Embedded Skeleton Reinforcement for Stator Housing Stiffness
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Solution Overview
Problem
Existing stator housings in electric motors lack sufficient structural reinforcement, leading to reduced stiffness and potential mechanical instability, especially in high-power compact motor applications.
Innovation Solution
A reinforced stator housing design featuring a structural skeleton embedded within the stator housing, constructed from continuous fiber composite, metal, or polymeric materials, which is fixed to a laminate steel core via an interlocking feature such as serrations or ribs, and includes a conduit system for fluid circulation to enhance cooling and mechanical support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional stator housing design is used, then the motor can be manufactured with simpler structure, but the stator housing lacks sufficient stiffness and structural integrity
Solution Approach 1:
The stator housing is constructed as a composite structure combining a polymeric housing material with an embedded structural skeleton made of high-stiffness material (metal or fiber-reinforced composite). This composite approach provides the necessary stiffness and strength while maintaining the benefits of polymeric materials such as corrosion resistance and ease of manufacturing.
Solution Approach 2:
The structural skeleton is embedded within the polymeric stator housing, creating a nested structure where the skeleton is positioned inside the housing cavity. This nesting approach allows the skeleton to provide internal reinforcement without increasing the external dimensions of the stator housing.
2Ease of manufacture
If the stator housing is made from polymeric material only, then manufacturing is easier, but mechanical stability and load-bearing capacity are reduced
Solution Approach 1:
The solution combines polymeric material with a structural skeleton made of high-strength material, creating a composite structure that leverages the manufacturing advantages of polymers while incorporating the mechanical stability of stronger materials. The polymeric housing can be injection molded or formed using conventional processes, while the skeleton provides the necessary structural support.
Solution Approach 2:
The structural skeleton is strategically positioned in regions of the stator housing where maximum mechanical support is needed, such as around the laminate steel core and at mounting locations. This localized reinforcement approach maintains ease of manufacture while improving mechanical stability only where required.
3Power
If the stator housing structure is simplified, then manufacturing cost is reduced, but thermal management capability is insufficient for high-power operations
Solution Approach 1:
The structural skeleton serves multiple functions: it provides mechanical reinforcement to the stator housing, acts as a thermal conduction path to dissipate heat from the laminate steel core, and serves as a mounting structure for other motor components. This multi-functionality allows high-power operation without requiring a separate complex cooling system.
Solution Approach 2:
The structural skeleton made of metal or thermally conductive composite material provides enhanced thermal conduction pathways within the polymeric housing. This allows efficient heat transfer from high-power motor components to the housing exterior for dissipation, enabling high-power operation while maintaining a relatively simple overall structure.
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 reinforced stator housing design significantly enhances the stiffness and structural integrity of the stator assembly, improving mechanical stability and thermal management, thereby supporting high-power operations in compact electric motors.
Implementation Method 1
The structural skeleton is thereby configured to reinforce the stator housing, i.e., support and enhance stiffness of the stator housing
Implementation Method 2
The interlocking feature may include serrations or ribs extending along the axis and in positive engagement with the stator housing
Implementation Method 3
The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core
Implementation Method 4
configured to circulate fluid around the laminate steel core
Implementation Method 5
The second set of members may be fixed to the first set of members via an adhesive or a weld
Implementation Method 6
The second set of members may be fixed to the first set of members via an adhesive or a weld
Implementation Method 7
The structural skeleton may be directly affixed to the laminate steel core, such as via insertion of one end of the structural skeleton directly into the laminate steel core
Data Source
AI summary
A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.