Stator assembly, a coolant fluid distribution ring element, a method, an electric machine and a vehicle

Patent metadata

Field	Value
Publication number	US-2025211040-A1
Application number	US-202418983535-A
Country	US
Kind code	A1
Filing date	Dec 17, 2024
Priority date	Dec 20, 2023
Publication date	Jun 26, 2025
Grant date	—

Abstract

A stator assembly for an electric machine, the stator assembly comprises a stator which extends between two end portions along a center axis of the stator assembly, corresponding to a rotational axis of the electric machine, the stator comprising a plurality of coolant fluid channels integrated in the stator, distributed in a circumferential direction around the stator and extending between the two end portions with openings at each end portion. The stator assembly further comprising a first coolant fluid distribution ring element provided at one of the end portions.

First claim

What is claimed is:

1 . A stator assembly for an electric machine, the stator assembly comprises a stator which extends between two end portions along a center axis of the stator assembly, corresponding to a rotational axis of the electric machine, the stator comprising:
a plurality of coolant fluid channels integrated in the stator, distributed in a circumferential direction around the stator and extending between the two end portions with openings at each end portion, the stator assembly further comprising: a first coolant fluid distribution ring element provided at one of the end portions, wherein the first coolant fluid distribution ring element comprises a first set of cavities distributed in a circumferential direction around the first coolant fluid distribution ring element, wherein each cavity of the first set of cavities is fluidly connected to a respective coolant fluid channel of a first set of the plurality of coolant fluid channels, wherein the first coolant fluid distribution ring element further comprises a first set of through holes distributed in the circumferential direction around the first coolant fluid distribution ring element and extending therethrough in a direction along the center axis, wherein each through hole of the first set of through holes is fluidly connected to a respective coolant fluid channel of a second set of the plurality of coolant fluid channels, and wherein the first coolant fluid distribution ring element further comprises a first ring element fluid channel which extends in the circumferential direction around the first coolant fluid distribution ring element, wherein the first ring element fluid channel is fluidly connected to each cavity of the first set of cavities and fluidly separated from each through hole of the first set of through holes.

2 . The stator assembly according to claim 1 , wherein the stator comprises a plurality of stator teeth, distributed in a circumferential direction around the stator and protruding in a radial direction towards or away from the center axis, wherein at least one coolant fluid channel of the plurality of coolant fluid channels is at least partly located in a stator tooth of the plurality of stator teeth.

3 . The stator assembly according to claim 1 , wherein the first coolant fluid distribution ring element comprises a plurality of tooth portions distributed in a circumferential direction around the first coolant fluid distribution ring element and protruding in a radial direction towards or away from the center axis.

4 . The stator assembly according to claim 3 , wherein at least one cavity of the first set of cavities and/or at least one through hole of the first set of through holes are/is at least partly located in a tooth portion of the plurality of tooth portions.

5 . The stator assembly according to claim 3 , wherein at least one tooth portion of the plurality of tooth portions has a curved profile, as seen in a sectional plane of the tooth portion which is perpendicular to a radial direction of the tooth portion.

6 . The stator assembly according to claim 5 , comprising at least one hairpin winding provided proximate the curved profile such that it follows the curved profile, as seen in the sectional plane of the tooth portion which is perpendicular to the radial direction of the tooth portion.

7 . The stator assembly according to claim 1 , wherein every second coolant fluid channel of the plurality of coolant fluid channels is a coolant fluid channel of the first set of the plurality of coolant fluid channels and wherein every other coolant fluid channel of the plurality of coolant fluid channels is a coolant fluid channel of the second set of the plurality of coolant fluid channels.

8 . The stator assembly according to claim 1 , wherein at least one cavity of the first set of cavities has a maximum radial extension (RE) in a radial direction from the first ring element fluid channel towards or away from the center axis and a maximum tangential extension (TE) in a tangential direction, wherein the maximum radial extension in the radial direction is longer than the maximum tangential extension in the tangential direction.

9 . The stator assembly according to claim 1 , wherein at least one coolant fluid channel of the plurality of coolant fluid channels has a maximum radial extension in a radial direction and a maximum tangential extension in a tangential direction, wherein the maximum radial extension in the radial direction is longer than the maximum tangential extension in the tangential direction.

10 . The stator assembly according to claim 1 , wherein at least one through hole of the first set of through holes, on a first axial side of the first coolant fluid distribution ring element which is facing the stator, has a maximum radial extension in a radial direction and a maximum tangential extension in a tangential direction, wherein the maximum radial extension in the radial direction is longer than the maximum tangential extension in the tangential direction.

11 . The stator assembly according to claim 10 , wherein the at least one through hole of the first set of through holes, on a second axial side of the first coolant fluid distribution ring element which is facing away from the stator, has an opening with an area size which is smaller than an area size of the at least one through hole on the first axial side.

12 . The stator assembly according to claim 11 , wherein the opening on the second axial side of the at least one through hole is circular.

13 . The stator assembly according to claim 1 , wherein the first ring element fluid channel is fluidly separated from each through hole of the first set of through holes by a cylindrically shaped wall and/or a radially extending disc-shaped wall of the first coolant fluid distribution ring element.

14 . The stator assembly according to claim 1 , wherein the first ring element fluid channel is provided at a radially outwardly facing portion of the first coolant fluid distribution ring element or at a radially inwardly facing portion of the first coolant fluid distribution ring element.

15 . The stator assembly according to claim 1 , wherein the first coolant fluid distribution ring element is made of a polymer material or a non-magnetic metallic material.

16 . The stator assembly according to claim 1 , further comprising:
a second coolant fluid distribution ring element provided at the other one of the end portions, wherein the second coolant fluid distribution ring element comprises a second set of cavities distributed in a circumferential direction around the second coolant fluid distribution ring element, wherein each cavity of the second set of cavities is fluidly connected to a respective coolant fluid channel of the second set of the plurality of coolant fluid channels, wherein the second coolant fluid distribution ring element further comprises a second set of through holes distributed in the circumferential direction around the second coolant fluid distribution ring element and extending therethrough in a direction along the center axis, wherein each through hole of the second set of through holes is fluidly connected to a respective coolant fluid channel of the first set of the plurality of coolant fluid channels, and wherein the second coolant fluid distribution ring element further comprises a second ring element fluid channel which extends in the circumferential direction around the second coolant fluid distribution ring element, wherein the second ring element fluid channel is fluidly connected to each cavity of the second set of ca

Assignees

• Volvo Truck Corp

Inventors

• Huang Zhe
• Andersson Rasmus
• Alm Ivar
• Lord John
• Hagstedt Dan

Classifications

• H02K15/12

  Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines · CPC title

• H02K15/02

  of stator or rotor bodies · CPC title

• H02K1/16

  Stator cores with slots for windings · CPC title

• H02K9/19

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

• H02K3/50

  Fastening of winding heads, equalising connectors, or connections thereto · CPC title