Stator Lamination Interface for Improved Heat Dissipation
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Solution Overview
Problem
Existing electric machines face challenges in efficiently cooling the stator, particularly in totally enclosed non-ventilated (TENV) configurations, which can lead to increased temperatures and reduced reliability due to inadequate heat dissipation.
Innovation Solution
The implementation of a thermally conductive encapsulant in the stator, combined with a forced fluid circuit and heat transfer structures, enhances heat dissipation through conduction, convection, and radiation, while also improving the structural robustness of the electric machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermally conductive encapsulant is used in the stator, then heat dissipation is enhanced, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the encapsulant material itself. The encapsulant simultaneously provides structural support, thermal conduction, and electrical insulation by integrating thermally conductive particles (such as aluminum oxide, boron nitride, or graphite) into the encapsulant matrix. This merging eliminates the need for separate thermal management components, thereby enhancing heat dissipation without proportionally increasing device complexity.
Solution Approach 2:
The patent employs composite materials for the encapsulant, specifically combining a base encapsulant material with thermally conductive particles. This composite structure allows the encapsulant to achieve superior thermal conduction properties while maintaining its structural and insulating functions. The composite encapsulant thus improves heat dissipation efficiency without requiring additional complex thermal management systems.
2Temperature
If forced fluid circuit and heat transfer structures are implemented, then thermal management is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the heat transfer structures with the stator core laminations themselves. The stator core is designed with integrated heat transfer features that work in conjunction with the forced fluid circuit, eliminating the need for separate, add-on heat transfer components. This integration simplifies the manufacturing process by reducing the number of assembly steps and components.
Solution Approach 2:
The stator core laminations serve multiple functions: they provide the magnetic circuit, structural support, and heat transfer pathways. The forced fluid circuit is designed to work with these multi-functional laminations, creating a unified thermal management system. This multi-functionality approach enhances thermal management while avoiding the manufacturing complexity of separate specialized components.
3Reliability
If thermally conductive encapsulant is used, then reliability is improved through better heat dissipation, but material selection complexity increases
Solution Approach 1:
The patent uses composite encapsulant materials that combine base encapsulant polymers with thermally conductive particles. This composite approach allows selection from well-established material systems with known properties and performance characteristics. The thermally conductive particles (aluminum oxide, boron nitride, graphite) are commercially available and well-characterized, making material selection more straightforward despite the enhanced functionality.
Solution Approach 2:
The patent adjusts the thermal conductivity parameter of the encapsulant by varying the concentration, size, and distribution of thermally conductive particles within the encapsulant matrix. This parameter-based approach allows optimization of heat dissipation performance while working within established material systems and manufacturing processes, thereby improving reliability without excessively complicating material selection.
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
This approach effectively reduces the production of heat in the stator and rotor, enhances the thermal management of electric machines, and increases their reliability and durability by ensuring efficient heat dissipation.
Implementation Method 1
The implementation of a thermally conductive encapsulant in the stator, combined with a forced fluid circuit and heat transfer structures, enhances heat dissipation through conduction, convection, and radiation
Implementation Method 2
The implementation of a thermally conductive encapsulant in the stator, combined with a forced fluid circuit and heat transfer structures, enhances heat dissipation through conduction, convection, and radiation
Implementation Method 3
The implementation of a thermally conductive encapsulant in the stator, combined with a forced fluid circuit and heat transfer structures, enhances heat dissipation through conduction, convection, and radiation
Data Source
AI summary
A stator and a method of fabricating a stator. In various cases, the stator includes an electromagnetic core comprising a stack of laminations. A dielectric layer can be coupled to one of a first or second lamination of the stack of laminations and a heat transfer layer, different from the dielectric layer, can be coupled to the other of the first lamination and the second lamination. An interface between the first lamination and the second lamination comprises the dielectric layer and the heat transfer layer.