Stator assembly for an electric machine

Patent metadata

Field	Value
Publication number	US-12580436-B2
Application number	US-202318299729-A
Country	US
Kind code	B2
Filing date	Apr 13, 2023
Priority date	Apr 22, 2022
Publication date	Mar 17, 2026
Grant date	Mar 17, 2026

Abstract

A stator assembly for an electric machine, including a sheet metal package, a winding assembly, and a collimator. The sheet metal package includes sheets and extends between a first and second axial end. The sheets include grooves forming groove pockets in the sheet metal package. The winding assembly extends through the groove pockets, the groove pockets at least partially including a first plurality of grooves configured as open grooves in a first axial region provided at the first axial end, a second plurality of grooves configured as open grooves in a second axial region provided at the second axial end, and a third plurality of grooves in at least one third axial region, the at least one third axial region lying between the first axial region and the second axial region. The third plurality of grooves are configured as closed grooves.

First claim

The invention claimed is:

1 . A stator assembly for an electric machine, the stator assembly being configured as an outer stator assembly for cooperating with an inner rotor and comprising:
a stator core formed from a sheet metal package; a winding assembly; and a radially sealing can connected to the sheet metal package, wherein the sheet metal package comprises sheets and extends between a first axial end and a second axial end, wherein the sheets comprise grooves, the grooves forming groove pockets in the sheet metal package, wherein the winding assembly extends through the groove pockets, the groove pockets at least partially comprising:
a first plurality of grooves in a first axial region provided at the first axial end of the stator core, the first plurality of grooves being configured as open grooves,
a second plurality of grooves in a second axial region provided at the second axial end of the stator core, the second plurality of grooves being configured as open grooves, and
a third plurality of grooves in at least one third axial region, the at least one third axial region lying between the first axial region and the second axial region, wherein the third plurality of grooves are configured as closed grooves adjacent to the first plurality of grooves at the first axial end and the second plurality of grooves at the second axial end, enclosed radially on all sides by one or more regions of the sheet, and are without a groove opening, and
wherein the can abuts a groove opening of the first plurality of grooves, a groove opening of the second plurality of grooves, and a radially inner enclosing portion of the third plurality of grooves.

2 . The stator assembly according to claim 1 , wherein the groove pockets in the first axial region comprise exclusively open grooves.

3 . The stator assembly according to claim 1 , wherein the groove pockets in the second axial region comprise exclusively open grooves.

4 . The stator assembly according to claim 1 , wherein the groove pockets in the third axial region comprise exclusively closed grooves.

5 . The stator assembly according to claim 1 , wherein the sheets with the open grooves comprise stator teeth, the stator teeth including a tooth neck and tooth heads at their radially inner end, between which stator teeth the open grooves are formed.

6 . The stator assembly according to claim 5 , wherein the stator teeth include a flaring at least in portions at a transition from the tooth neck to the tooth head.

7 . The stator assembly according to claim 1 , wherein the can comprises a plastic.

8 . The stator assembly according to claim 1 , wherein the can seals the stator assembly on a radially inner side of the sheet metal package.

9 . The stator assembly according to claim 1 , comprising a housing,
wherein the housing comprises an inlet and an outlet for a coolant, wherein the housing comprises the can, and wherein the housing is configured so as to be fluid-tight between the inlet and the outlet in order to allow a cooling of the stator assembly by the coolant.

10 . The stator assembly according to claim 9 , wherein the groove pockets are fluidically connected to the inlet and the outlet in order to allow a coolant flow of the coolant through the groove pockets.

11 . The stator assembly according to claim 1 , wherein the first axial region and/or the second axial region extends axially at least 5 mm.

12 . The stator assembly according to claim 1 , wherein the first plurality of grooves and/or the second plurality of grooves includes at least 5 grooves.

13 . The stator assembly according to claim 1 , wherein the third plurality of grooves includes at least 4 grooves.

14 . An electric machine comprising a stator assembly according to claim 1 and a rotor assembly.

15 . The stator assembly according to claim 1 , wherein the can is connected to the sheet metal package by an adhesive connection or by an additional adhesive.

16 . The stator assembly according to claim 7 , wherein the plastic is a fiber-reinforced plastic.

17 . The stator assembly according to claim 11 , wherein the first axial region and/or the second axial region extends axially at least 10 mm.

18 . The stator assembly according to claim 12 , wherein the first plurality of grooves and/or the second plurality of grooves includes at least 7 grooves.

19 . The stator assembly according to claim 1 , wherein the third plurality of grooves are enclosed on all sides by one or more regions of the sheet, wherein the at least one third axial region is continuous between the first axial end and the second axial end and adjacent to the first axial end and the second axial end, wherein the third axial region comprises the third plurality of grooves, and wherein each sheet of the sheet metal package in the third axial region comprises a respective closed groove of the third plurality of grooves.

20 . The stator assembly according to claim 1 , wherein the can abuts the sheet metal package along an entire circumference of the can for an entire axial length of the sheet metal package.

Assignees

• Porsche Ag

Inventors

• Engelhardt Tobias
• Reinlein Michael
• Bauer David
• Wende Johannes
• Hubert Thomas

Classifications

• H02K5/203

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

• H02K9/197

  in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator · CPC title

• H02K2201/09

  Magnetic cores comprising laminations characterised by being fastened by caulking · CPC title

• H02K9/22

  by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges · CPC title

• H02K9/19

  for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil · CPC title