Water Pump Overmolded Stator Heat Sink Design
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Solution Overview
Problem
Conventional water pumps with rare earth metals in the rotor and stator are prone to damage from fluids, requiring additional packaging and complex assembly, and suffer from inefficiencies in heat dissipation and vibration resistance.
Innovation Solution
A water pump design featuring an over-molded stator stack, wires, and pins with a cylindrical ring boot, integrated heat sink, and snap-fit assembly, which reduces parts, enhances heat transfer, and improves vibration resistance by eliminating air gaps and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rare earth metals are used in rotor and stator, then magnetic performance is improved, but susceptibility to fluid damage increases
Solution Approach 1:
A magnetic seal is introduced as an intermediary component between the rare earth metal magnets and the fluid environment. This seal acts as a protective barrier that prevents direct contact between the fluid and the vulnerable rare earth metals, thereby maintaining magnetic performance while protecting against fluid damage and corrosion.
2Reliability
If additional packaging is added to protect rare earth metals, then reliability is improved, but device complexity increases
Solution Approach 1:
The magnetic seal is integrated directly into the stator structure, merging the protective function with the existing stator component. This integration eliminates the need for separate protective packaging layers and simplifies the overall assembly process while maintaining reliable protection of the rare earth metals.
3Ease of manufacture
If conventional assembly methods are used, then manufacturing is simpler, but heat dissipation efficiency decreases
Solution Approach 1:
The stator is designed with differentiated local zones: a magnetic seal region for protection, a winding region for electrical components, and a heat dissipation region with optimized thermal pathways. This local quality differentiation allows heat to be efficiently conducted away from critical components while maintaining simple overall manufacturing processes.
4Ease of operation
If air gaps are present between components, then assembly is easier, but heat transfer efficiency decreases
Solution Approach 1:
The air gaps between the magnetic seal, windings, and stator body are eliminated by taking out the insulating air medium and replacing it with direct thermal contact through the integrated stator structure. This creates continuous heat transfer pathways while the magnetic seal maintains necessary magnetic and fluid sealing functions.
5Ease of manufacture
If standard die-casted housing is used, then manufacturing is conventional, but weight and vibration resistance are insufficient
Solution Approach 1:
The pump housing transitions from conventional die-cast metal to composite materials such as reinforced plastics or carbon-fiber composites. These composite materials provide equivalent or superior structural strength and vibration resistance while significantly reducing the overall weight of the pump assembly.
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 design results in a more compact, lightweight pump with improved heat dissipation and reduced vibration, while eliminating the need for screws and additional sealing, enhancing stability and efficiency.
Implementation Method 1
the stator stack, the wires and pins are over molded with a second plastic material to form a cylindrical ring boot and a heat sink that seals a cylindrical opening of the boot
Implementation Method 2
The rotor is in communication with an impeller for moving a fluid. The fluid enters the pump through an inlet in a volute, contacted with an impeller and moved through an outlet in the volute
Data Source
AI summary
Water pump with an impeller driven by an electrical machine comprising a housing cap and a volute with an input and an output and a boot hosting a stator and a rotor of the electrical machine and an electronic board mounted at the side apart from the impeller and covered by the cap housing, characterized in that the stator stack is over molded with a first plastic material and at least the stator stack, the wires and pins are over molded with a second plastic material to form a cylindrical ring boot and a heat sink that seals a cylindrical opening of the boot.