Stator Coolant Sleeve Assembly With Spring-Formed Cooling Channels

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Solution Overview

Problem

Existing coolant sleeves for electric motor stators require complex and costly manufacturing processes due to the need for integrated cooling channels, which increases production complexity and cost.

Innovation Solution

A coolant sleeve assembly that includes a sleeve surrounding the stator and a spring wound around the sleeve, where the spring defines at least one coolant channel wall separate from the sleeve to conduct coolant and cool the stator.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If coolant channels are integrated into the sleeve through machining or casting, then cooling function is achieved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvecooling functionVSAvoidmanufacturing cost and complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The coolant channel structure is segmented from the sleeve. Instead of integrating channels into the sleeve body, the patent uses a separate spring component that defines the coolant channel walls. This segmentation allows the sleeve to be a simple tubular structure while the spring provides the cooling function, thereby simplifying sleeve manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coolant channel function is extracted from the sleeve and assigned to a separate spring component. The spring is wound around the sleeve and defines the coolant channel walls independently, allowing the sleeve to be manufactured without complex channel formation processes.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If coolant channels are formed in the sleeve, then coolant conduction is enabled, but device complexity increases

Engineering Contradiction:

Improvecoolant conductionVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The device is segmented into distinct functional components: the sleeve provides structural support and containment, while the separate spring component provides the coolant channel function. This segmentation reduces the complexity of each individual component and simplifies assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spring component serves multiple functions: it defines the coolant channel walls, provides structural support for the channel, and maintains the necessary geometry for coolant flow. This multi-functionality reduces the overall device complexity by consolidating functions into a single component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution simplifies the manufacturing process by eliminating the need for integrated cooling channels in the sleeve, reducing production costs and complexity while effectively cooling the stator.

Implementation Method 1

The spring may at least partially define at least one coolant channel wall separate from the sleeve to conduct coolant around the sleeve and thereby cool the stator

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP4498579A1Electric motors including coolant sleeve assembies, coolant sleeve assemblies, and methods therefor

Publication Date: 2025.01.29 ALLISON TRANSMISSION INC

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AI summary

Electric motors, coolant sleeve assemblies, and methods of cooling a stator of an electric motor are disclosed. An electric motor may include a stator and a coolant sleeve assembly. The coolant sleeve assembly may include a sleeve and a spring. The sleeve may at least partially surround the stator and the spring may be wound around the sleeve.