Electric machine having a plastic body

Patent metadata

Field	Value
Publication number	US-12126240-B2
Application number	US-202017602376-A
Country	US
Kind code	B2
Filing date	Mar 4, 2020
Priority date	Apr 23, 2019
Publication date	Oct 22, 2024
Grant date	Oct 22, 2024

Abstract

An electric machine includes a housing, a stator, a rotor arranged radially within the stator, and a plastic body fixing the stator relative to the housing. The plastic body is electrically insulating. Further, the plastic body radially surrounds an outside of at least one soft magnetic core of the stator and first and second winding overhangs of the stator, and axially surrounds an end face of the first winding overhangs and an end face of the second winding overhangs. Additionally, the plastic body defines at least one channel for accommodating a coolant, the at least one channel having a first portion extending circumferentially along at least 40% of the end face of the first winding overhangs, a second portion extending along an outer circumferential surface of the stator, and a third portion extending circumferentially along at least 40% of the end face of the second winding overhangs.

First claim

The invention claimed is:

1. An electric machine ( 1 ), comprising:
a housing ( 2 );
a stator ( 4 ) fixed relative to the housing ( 2 ), the stator having at least one soft magnetic core ( 6 ), first winding overhangs ( 7 a ), and second winding overhangs ( 7 b );
a rotor ( 5 ) arranged radially within the stator ( 4 ); and
a plastic body ( 3 ) fixing the stator ( 4 ) relative to the housing ( 2 ),
wherein the plastic body ( 3 ) is electrically insulating,
wherein the plastic body ( 3 ) radially surrounds an outside of the at least one soft magnetic core ( 6 ) of the stator ( 4 ) and the first and second winding overhangs ( 7 a , 7 b ) of the stator ( 4 ) and axially surrounds an end face ( 9 a ) of the first winding overhangs ( 7 a ) and an end face ( 9 b ) of the second winding overhangs ( 7 b ), and
wherein the plastic body ( 3 ) defines at least one channel ( 8 ) for accommodating a coolant, the at least one channel ( 8 ) having a first portion extending circumferentially along at least forty percent of the end face ( 9 a ) of the first winding overhangs ( 7 a ), a second portion extending along an outer circumferential surface ( 10 ) of the stator ( 4 ), and a third portion extending circumferentially along at least forty percent of the end face ( 9 b ) of the second winding overhangs ( 7 b ).

2. The electric machine ( 1 ) of claim 1 , wherein an inlet ( 11 ) for the coolant is at the end face ( 9 a ) of the first winding overhangs ( 7 a ), and wherein an outlet ( 12 ) for the coolant is at the end face ( 9 b ) of the second winding overhangs ( 7 b ).

3. The electric machine ( 1 ) of claim 1 , wherein an axial width of the second portion of the at least one channel ( 8 ) along the outer circumferential surface ( 10 ) of the stator ( 4 ) is at least three times larger than a radial depth of the second portion of the at least one channel ( 8 ) at the outer circumferential surface ( 10 ) of the stator ( 4 ).

4. The electric machine ( 1 ) of claim 1 , wherein the at least one channel ( 8 ) is an indentation in an outer surface of the plastic body ( 3 ) and is configured for guiding the coolant between the housing ( 2 ) and the plastic body ( 3 ).

5. The electric machine ( 1 ) of claim 1 , wherein the plastic body ( 3 ) is at least radially outside of a first axial ridge ( 14 a ) of the housing ( 2 ) proximate the first winding overhangs ( 7 a ), and wherein the plastic body ( 3 ) is at least radially outside of a second axial ridge ( 14 b ) of the housing ( 2 ) proximate the second winding overhangs ( 7 b ).

6. The electric machine ( 1 ) of claim 5 , further comprising:
a first seal ( 13 a ) between the first axial ridge ( 14 a ) and the plastic body ( 3 ); and
a second seal ( 13 b ) between the second axial ridge ( 14 b ) and the plastic body ( 3 ).

7. The electric machine ( 1 ) of claim 6 , wherein one or both of the first axial ridge ( 14 a ) and the second axial ridge ( 14 b ) is rotationally fixed to the plastic body ( 3 ) to support torque of the stator ( 4 ).

8. The electric machine ( 1 ) of claim 7 , wherein an external toothing ( 15 ) at least partially circumferentially extends around the housing ( 2 ) proximate one or both of the first axial ridge ( 14 a ) and the second axial ridge ( 14 b ), the external toothing ( 15 ) being engageable with an internal toothing ( 16 ) on the plastic body ( 3 ).

9. The electric machine ( 1 ) of claim 6 , further comprising a bearing ( 18 ) proximate one or both of the first axial ridge ( 14 a ) and the second axial ridge ( 14 b ).

10. The electric machine ( 1 ) of claim 1 , further comprising at least one electrical line ( 17 a , 17 b , 17 c ) for conducting an electric current to and from the stator ( 4 ), the at least one channel ( 8 ) extending along one or more of the at least one electrical line ( 17 a , 17 b , 17 c ).

11. The electric machine ( 1 ) of claim 1 , wherein the plastic body ( 3 ) comprises thermally conductive fillers.

12. The electric machine ( 1 ) of claim 1 , wherein the housing ( 2 ) has multiple pieces including at least one first housing cover ( 2 a ) and a housing shell section ( 2 c ).

13. The electric machine ( 1 ) of claim 12 , further comprising:
a third seal ( 13 c ) and a fourth seal ( 13 d ), the third seal ( 13 c ) and the fourth seal ( 13 d ) being arranged between the housing ( 2 ) and the plastic body ( 3 ) at a section ( 3 a ) of the plastic body ( 3 ) that is at least partially axially between one of the at least one first housing cover ( 2 a ) and the housing shell section ( 2 c ).

14. The electric machine ( 1 ) of claim 1 , wherein the second portion of the at least one channel ( 8 ) extends helically along the outer circumferential surface ( 10 ) of the stator ( 4 ).

15. The electric machine ( 1 ) of claim 1 , wherein the end face ( 9 a ) of the first winding overhangs ( 7 a ) is a first axial end of the stator ( 4 ) and the end face ( 9 b ) of the second winding overhangs ( 7 b ) is a second axial end of the stator ( 4 ).

16. The electric machine ( 1 ) of claim 1 , wherein the first portion of the at least one channel ( 8 ) extends axially outside the stator ( 4 ) and circumferentially along the at least forty percent of the end face ( 9 a ) of the first winding overhangs ( 7 a ), and the third portion of the at least one channel ( 8 ) extends axially outside the stator ( 4 ) and circumferentially along the at least forty percent of the end face ( 9 b ) of the second winding overhangs ( 7 b ).

Assignees

• Zahnradfabrik Friedrichshafen

Inventors

• Wehlen Timo
• Lübke Eckhardt
• Hölscher Andreas
• Jelinewski Martin
• Till Manfred

Classifications

• H02K5/163

  radially supporting the rotary shaft at only one end of the rotor (H02K5/165, H02K5/167, H02K5/173 take precedence) · CPC title

• H02K5/203

  specially adapted for liquids, e.g. cooling jackets · CPC title

• H02K9/223

  Heat bridges · CPC title

• H02K11/21

  Devices for sensing speed or position, or actuated thereby (specially adapted for machines having non-mechanical commutating devices H02K29/06, H02K29/14) · CPC title

• H02K5/24

  specially adapted for suppression or reduction of noise or vibrations · CPC title