Stator Solder Connection for Electric Machine Thermal Management
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Solution Overview
Problem
Existing electric machine stator cooling systems face inefficiencies due to limited thermal conductivity and mechanical stability issues between the stator and cooler, leading to potential system failure from differential expansions and thermal conduction losses.
Innovation Solution
A method involving partial coating of the stator and cooler with a solder layer, followed by heating to create a solder connection, ensuring a stable thermal and mechanical bond, which enhances heat dissipation and mechanical support, allowing for increased motor power by improving thermal coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally conductive adhesive is used to bond stator elements to the cooler, then thermal conduction is improved, but mechanical stability deteriorates due to differential expansion and temperature gradients
Solution Approach 1:
The patent changes the bonding method from adhesive bonding to soldering, fundamentally altering the connection parameters. The solder layer (tin or tin alloy) is applied to the stator elements and melted to create a metallurgical bond with the cooler, achieving both superior thermal conduction and mechanical stability that withstands temperature gradients and differential expansion without deteriorating.
Solution Approach 2:
The patent creates a composite structure by coating the stator elements with a solder material layer (tin or tin alloy). This composite approach combines the electrical and thermal conductivity of the solder with the structural properties of the stator elements, forming a unified assembly that maintains both thermal performance and mechanical integrity under thermal stress.
2Ease of manufacture
If adhesive bonding is used to connect stator to cooler, then assembly is simplified, but thermal conductivity is insufficient leading to power loss
Solution Approach 1:
The patent changes the thermal conduction parameter by replacing adhesive bonding with soldering. The solder layer provides significantly higher thermal conductivity compared to thermally conductive adhesives, thereby reducing thermal resistance and minimizing power loss while maintaining manufacturing feasibility through a standardized coating and heating process.
3Reliability
If soldering is implemented to improve thermal conductivity, then thermal conduction improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies the solder layer (tin or tin alloy) to the stator elements in advance, before assembly with the cooler. This preliminary coating ensures uniform distribution of the solder material and simplifies the subsequent bonding process, as the solder is already in place to receive the cooler during the heating and melting stage, thereby reducing overall manufacturing complexity.
4Ease of manufacture
If aggressive flux agents are used in soldering, then soldering effectiveness improves, but damage to temperature-sensitive components occurs
Solution Approach 1:
The patent creates a protected environment during soldering by covering the stator elements with a flux-free solder layer (tin or tin alloy). This inert barrier prevents oxidation and eliminates the need for aggressive flux agents that could damage temperature-sensitive components, while still enabling effective soldering through the melting and bonding of the solder material to the cooler.
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 solder connection provides superior thermal conductivity and mechanical stability, enabling effective heat dissipation and increased motor power while preventing damage to temperature-sensitive components and eliminating the need for aggressive flux agents.
Implementation Method 1
the cooler is heated to the melt temperature of the layer of solder
Implementation Method 2
heating to create a solder connection
Implementation Method 3
The solder connection provides superior thermal conductivity and mechanical stability, enabling effective heat dissipation
Data Source
AI summary
A method for soldering a stator of an electric machine to a cooler is described. Firstly, the stator and/or the cooler is coated, at least partially, with a layer of solder. Then, the stator is brought together with the cooler such that the layer of solder is between the stator and the cooler. Finally, the cooler is heated to the melt temperature of the layer of solder in order to produce a solder connection between the stator and the cooler. The cooler can also act as support. Furthermore, a stator for an electric machine, comprising a stator support and a solder connection between the stator and the stator support is described.