Radial Flux Motor Stator Encapsulation for Axial Fastening

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing radial flux motors face challenges in securing the stator reliably, especially in high-voltage applications where heat generation and magnetic forces pose additional difficulties.

Innovation Solution

A stator arrangement for a radial flux motor that includes a stator housing, a stator, and an encapsulation body. The stator is arranged on a circumferential portion of the stator housing and is encapsulated within the housing. The encapsulation body is form-fittingly connected to the stator housing, securing the stator at least in the axial direction through a friction-locking mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the stator is secured using conventional fastening methods, then the stator can be fixed in position, but the reliability is insufficient under high magnetic forces and thermal expansion conditions

Engineering Contradiction:

Improvestator fastening reliabilityVSAvoidmagnetic forces and heat-induced temperature expansions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The encapsulation body merges multiple functions into a single component: it provides mechanical fastening of the stator, thermal management through heat-conductive material, and structural support. This integrated approach replaces conventional separate fastening mechanisms with a unified encapsulation solution that addresses multiple challenges simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The encapsulation body is made from heat-conductive encapsulation material that combines mechanical bonding properties with thermal conduction capabilities. This composite material approach allows the single component to provide both secure mechanical fastening under magnetic forces and effective heat dissipation from the stator windings.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple separate components are used to secure the stator, then the fastening can be adjusted, but the device complexity increases

Engineering Contradiction:

Improvestator fasteningVSAvoidstator arrangement structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The encapsulation body consolidates multiple separate components (fastening elements, thermal interface material, structural supports) into a single integrated component. This merging reduces the number of parts, simplifies assembly, and lowers device complexity while maintaining or improving fastening reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The encapsulation body serves multiple functions simultaneously: mechanical fastening, thermal conduction, structural support, and insulation. This multi-functionality eliminates the need for separate dedicated components for each function, thereby reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If conventional stator mounting methods are used, then the production process can be simplified, but power losses increase due to poor thermal connection

Engineering Contradiction:

Improveproduction process simplicityVSAvoidpower losses from poor thermal connection

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The use of heat-conductive encapsulation material provides both ease of manufacture (as a single castable or moldable material) and improved thermal connection (through inherent heat conduction properties). This composite material approach eliminates the need for separate thermal interface materials while reducing power losses.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The encapsulation body combines structural support and thermal management functions into one component, maintaining production simplicity while ensuring good thermal connection between the stator and the housing, thereby reducing energy losses.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a reliable and cost-effective method for securing the stator, reducing power losses, and simplifying the production process, while also improving thermal connection and heat dissipation.

Implementation Method 1

The encapsulation body (50) is form-fittingly connected to the stator housing (20) in such a manner that the stator (40) is secured at least in the axial direction (2) in the stator housing (20) by the encapsulation body (50)

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20250030281A1Stator arrangement for a radial flux motor

Publication Date: 2025.01.23 BORGWARNER INC

AI summary

A stator arrangement (10) for a radial flux motor (100) having an axis of rotation (100a). The stator arrangement (10) includes a stator housing (20), a stator (40) and an encapsulation body (50). The stator housing (20) defines a circumferential portion (30) for receiving the stator. The stator (40) is arranged on the circumferential portion (30). Furthermore, the stator (40) is encapsulated in the stator housing (20), wherein the encapsulation body (50) is form-fittingly connected to the stator housing (20) in such a manner that the stator (40) is secured at least in the axial direction (2) in the stator housing (20) by the encapsulation body (50).