Electrical machine

Patent metadata

Field	Value
Publication number	US-11581771-B2
Application number	US-201816614678-A
Country	US
Kind code	B2
Filing date	May 18, 2018
Priority date	May 19, 2017
Publication date	Feb 14, 2023
Grant date	Feb 14, 2023

Abstract

An electrical machine may include a comprise a rotor, a stator, a coolant distributor chamber and a coolant collector chamber. The rotor may be rotated about an axis of rotation that defines an axial direction of the electrical machine. The stator may comprise a plurality of stator windings. The coolant collector chamber may be axially arranged at a distance from the coolant distributor chamber. The coolant distributor chamber may communicate fluidically with the coolant collector chamber by way of least one cooling channel through which a coolant can flow. The at least one cooling channel and the at least one stator winding may be embedded in a plastic mass consisting of an electrically insulating plastic for thermal coupling to the coolant.

First claim

The invention claimed is:

1. An electrical machine, comprising:
a rotor configured to be rotatable about an axis of rotation that defines an axial direction of the electrical machine,
a stator including stator windings,
wherein, for thermal coupling, at least one cooling channel and at least one of the stator windings are embedded into a plastics compound including an electrically insulating plastic
wherein the stator has stator teeth that extend along the axial direction, are arranged spaced apart from one another along a circumferential direction of the rotor, and support the stator windings,
a coolant distributor chamber and a coolant collector chamber arranged at an axial distance to said coolant distributor chamber, wherein the coolant distributor chamber for cooling the stator windings communicates fluidically with the coolant collector chamber by the at least one cooling channel through which a coolant can flow, and
wherein the plastics compound comprising the at least one cooling channel and the at least one stator winding arranged in an intermediate space, which is embodied between the stator teeth that are adjacent in the circumferential direction,
wherein at least one of the stator winding includes at least one axial end portion that protrudes axially from the intermediate space and into at least one of the coolant distributor chamber and the coolant collector chamber, and the plastics compound projects axially from the intermediate space and at least partially surrounds and embeds the at least one axial end portion to at least partially limit the at least one of the coolant distributor chamber and the coolant collector chamber, so that the at least one axial end portion of the at least one stator winding is electrically insulated with respect to the coolant during operation of the electrical machine.

2. The electrical machine of claim 1 , wherein, for the thermal coupling to the stator windings, at least one of the coolant distributor chamber and the coolant collector chamber is at least partially arranged in the one plastics compound.

3. The electrical machine of claim 1 , wherein the intermediate space comprises a first partial space in which the at least one stator winding is arranged, and a second partial space in which the at least one cooling channel is arranged, and
a positioning aid is arranged between the two partial spaces such that the at least one cooling channel can be positioned in the second partial space.

4. The electrical machine of claim 3 , wherein the positioning aid comprises two projections that are formed on two adjacent stator teeth in the circumferential direction, and
the two projections face each other in the circumferential direction and project into the intermediate space beyond circumferential ends of the at least one cooling channel to position the cooling channel and provide a radial stop for the at least one cooling channel.

5. The electrical machine of claim 1 , wherein the at least one of the coolant distributor chamber and the coolant collector chamber surrounds the at least one axial end portion of the at least one stator winding in a U-shaped manner.

6. The electrical machine of claim 1 , wherein the plastics compound at least partially bounds at least one of the coolant distributor chamber and the coolant collector chamber.

7. The electrical machine of claim 1 , wherein in the intermediate space the plastics compound includes a single plastic, and
an additional electrical insulation including an electrically insulating material is arranged in the intermediate space.

8. The electrical machine of claim 7 , wherein the additional electrical insulation is arranged between at least one of the stator windings and the stator teeth.

9. The electrical machine of claim 1 , wherein the electrically insulating plastic includes at least one of a thermosetting plastic and a thermoplastic.

10. The electrical machine of claim 1 , wherein at least one cooling channel and the plastics compound are provided in the intermediate space between two of the stator teeth that are respectively adjacent in the circumferential direction.

11. The electrical machine of claim 1 , wherein the at least one cooling channel is arranged at least one of radially outside and radially within a respective one of the stator windings in the intermediate space.

12. The electrical machine of claim 1 , wherein the at least one cooling channel includes a tubular body that surrounds a tubular body interior space, and
wherein at least one separating element divides the tubular body interior space into at least two partial cooling channels that are fluidically separated from one another is formed on the tubular body.

13. The electrical machine of claim 12 , wherein the tubular body includes a flat tube, and
wherein, in a cross section perpendicular to the axial direction, at least one wide side of the flat tube extends substantially perpendicularly to the radial direction.

14. The electrical machine of claim 1 , wherein the plastics compound is an injection molding compound consisting of the electrically insulating plastic.

15. The electrical machine claim 1 , wherein the stator comprises a stator body, and
wherein the plastics compound consisting of the electrically insulating plastic is arranged on an outer circumferential side of the stator body and forms an outer coating on said outer circumferential side.

16. The electrical machine of claim 1 , wherein the coolant distributor chamber communicates fluidically with the coolant collector chamber by a plurality of cooling channels.

17. The electrical machine of claim 16 , wherein the plurality of cooling channels extends spaced apart from one another along the axial direction.

18. The electrical machine of claim 16 , wherein the plurality of cooling channels are arranged at a distance from one another along a circumferential direction of the stator.

19. The electrical machine of claim 1 , wherein at least one of the coolant distributor chamber and the coolant collector chamber is arranged adjacent to the stator body or stator exclusively in an axial extension thereof and does not proj ect beyond said stator body or stator along a radial direction thereof.

20. The electrical machine of claim 1 , wherein at least one stator winding is designed in such a manner that it is insulated electrically from the coolant and from the stator body at least in the region within the respective intermediate space during operation of the electrical machine.

21. The electrical machine of claim 20 , wherein said electrical insulation of the at least one of the stator windings from the stator body, also from the stator teeth bounding the intermediate space, is formed by at least one of the plastics compound and an additional electrical insulation.

22. The electrical machine of claim 7 ,
the additional electrical insulation within the intermediate space extends over the entire length of the intermediate space, as measured along the axial direction, such that said insulation insulates at least one of the stator windings from the stator body and from stator teeth of the stator bounding the respective intermediate space.

23. The electrical machine of claim 7 , wherein the additional electrical insulation surrounds at least one of the stator windings within the intermediate space at least over an entire length of the intermediate space along the circumference thereof.

24. The electrical machine of cl

Assignees

• Mahle Int Gmbh

Inventors

• Hoerz Mirko
• Steurer Hans-Ulrich
• Sonntag Josef
• Stojan Markic
• Licen Andrej
• Medvescek Aleks
• Sever Peter
• Grabherr Philip

Classifications

• H02K1/20

  with channels or ducts for flow of cooling medium · CPC title

• B60K1/00

  Arrangement or mounting of electrical propulsion units (B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00) · CPC title

• H02K3/24 Primary

  with channels or ducts for cooling medium between the conductors · CPC title

• H02K5/1732

  radially supporting the rotary shaft at both ends of the rotor (H02K5/1737 takes precedence) · CPC title

• H02K9/227

  Heat sinks · CPC title