USOO880338 OB2

(12) United States Patent (10) Patent No.: US 8,803,380 B2

Chamberlin et al. (45) Date of Patent: Aug. 12, 2014
(54) ELECTRIC MACHINE MODULE COOLNG 3,748,507 A 7, 1973 Sieber
SYSTEMAND METHOD 4,038,570 A 7/1977 Durley, III
5,081,382 A 1/1992 Collings et al.
5, 180,004 A 1/1993 Nguyen
(75) Inventors: Bradley D. Chamberlin, Pendleton, IN 5,207,121 A 5, 1993 Blen
(US); David A. Fulton, Anderson, IN 5,293,089 A 3, 1994 Frister
(US) 5,372,213 A 12/1994 HaSebe et al.
5,519,269 A 5/1996 Lindberg
(73) Assignee: Remy Technologies, LLC, Pendleton, 5,616,973 A 4/1997 Khazanov
5,859,482 A 1/1999 Crowell et al.
IN (US) 5,923,108 A 7/1999 Matake et al.
(*) Notice: Subject to any disclaimer, the term of this (Continued)
patent is extended or adjusted under 35 FOREIGN PATENT DOCUMENTS
U.S.C. 154(b) by 145 days.
JP 05-103445 A 4f1993
(21) Appl. No.: 13/488,327 JP 05-292.704 A 11, 1993

(22) Filed: Jun. 4, 2012 (Continued)

OTHER PUBLICATIONS
(65) Prior Publication Data
US 2012/0305226A1 Dec. 6, 2012 International Search Report, Received Jul. 31, 2012.
(Continued)
Related U.S. Application Data
(60) Provisional application No. 61/493,310, filed on Jun. Primary Examiner — Hanh Nguyen
3, 2011. (74) Attorney, Agent, or Firm — Greenberg Traurig, LLP
(51) Int. C. (57) ABSTRACT
HO2K9/00 (2006.01) Embodiments of the invention provide an electric machine
(52) U.S. C. module. The module can include a housing that can define a
USPC ............................................... 310/54; 310/64 machine cavity. The housing can include a coolantjacket that
(58) Field of Classification Search contains a first coolant. A coolant Sump can be in fluid com
USPC .......................... 310/52, 54,58, 64, 60 A, 61 munication with the machine cavity and can contain a second
See application file for complete search history. coolant that is different than the first coolant. The coolant
Sump can be in thermal communication with the coolant
(56) References Cited jacket. An electric machine can be positioned within the
U.S. PATENT DOCUMENTS
machine cavity. The electric machine can include a stator
assembly, a rotor assembly, and a shaft. The module can also
2,080,678 A 5, 1937 Van Hornet al. include at least one coolant channel, at least one shaft chan
2.264,616 A 12/1941 Buckbee nel, and at least one rotor channel.
3,447,002 A 5/1969 Ronnevig
3,525,001 A 8, 1970 Erickson 15 Claims, 11 Drawing Sheets

26 80 67 O
66 1.

NLI

th HMN

50
 US 8,803.380 B2
Page 2

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 US 8,803.380 B2
Page 3

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U.S. Patent Aug. 12, 2014 Sheet 1 of 11 US 8,803,380 B2
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 US 8,803,380 B2
1. 2
ELECTRIC MACHINE MODULE COOLING FIG. 9 is a perspective view of a rotor assembly according
SYSTEMAND METHOD to one embodiment of the invention.
FIG. 10 is a cross-sectional view of an electric machine
RELATED APPLICATIONS module according to one embodiment of the invention.
FIG. 11 is a side view of an electric machine module
This application claims priority under 35 U.S.C. S 119 to according to one embodiment of the invention.
U.S. Provisional Patent Application No. 61/493,310 filed on FIG. 12 is a cross-sectional view of an electric machine
Jun. 3, 2011, the entire contents of which is incorporated module according to one embodiment of the invention.
herein by reference. 10 DETAILED DESCRIPTION
BACKGROUND
Before any embodiments of the invention are explained in
Electric machines, often contained withina machine cavity detail, it is to be understood that the invention is not limited in
of a housing, generally include a stator and a rotor. For some its application to the details of construction and the arrange
15 ment of components set forth in the following description or
electric machines, the stator can be secured to the housing illustrated in the following drawings. The invention is capable
different coupling techniques to generally secure the electric of other embodiments and of being practiced or of being
machine within the housing. During operation of Some elec carried out in various ways. Also, it is to be understood that
tric machines, heatenergy can by generated by both the stator the phraseology and terminology used herein is for the pur
and the rotor, as well as other components of the electric po pose of description and should not be regarded as limiting.
machine. For some electric machines, the increase in heat The use of “including.” “comprising,” or “having and varia
energy can, at least partially, impact electric machine opera tions thereof herein is meant to encompass the items listed
tions. thereafter and equivalents thereofas well as additional items.
Unless specified or limited otherwise, the terms “mounted.”
SUMMARY 25 “connected,” “supported,” and “coupled' and variations
thereof are used broadly and encompass both direct and indi
Some embodiments of the invention provide an electric rect mountings, connections, Supports, and couplings. Fur
machine module. The module can include a housing, which ther, “connected and “coupled are not restricted to physical
can define a machine cavity. In some embodiments, the hous or mechanical connections or couplings.
ing can include at least a portion of a coolantjacket, which can 30 The following discussion is presented to enable a person
be configured to contain a first coolant. A coolant Sump can be skilled in the art to make and use embodiments of the inven
in fluid communication with the machine cavity and can be tion. Various modifications to the illustrated embodiments
capable of containing a second coolant that is different from will be readily apparent to those skilled in the art, and the
the first coolant. In some embodiments, the coolant Sump can generic principles herein can be applied to other embodi
be in thermal communication with the coolantjacket. In some 35 ments and applications without departing from embodiments
embodiments, an electric machine can be positioned within of the invention. Thus, embodiments of the invention are not
the machine cavity and can be at least partially enclosed by intended to be limited to embodiments shown, but are to be
the housing. The electric machine can include a stator assem accorded the widest scope consistent with the principles and
bly, a rotor assembly that can be at least partially circum features disclosed herein. The following detailed description
scribed by a portion of the stator assembly, and a shaft being 40 is to be read with reference to the figures, in which like
that can be operatively coupled to the rotor assembly. In some elements in different figures have like reference numerals.
embodiments, an air gap can be defined between a portion of The figures, which are not necessarily to scale, depict selected
the stator assembly and a portion of the rotor assembly. In embodiments and are not intended to limit the scope of
Some embodiments, the coolant Sump can positioned so that embodiments of the invention. Skilled artisans will recognize
no material amounts of the second coolant can enter the air 45 the examples provided herein have many useful alternatives
gap. that fall within the scope of embodiments of the invention.
FIGS. 1 and 2 illustrate an electric machine module 10
DESCRIPTION OF THE DRAWINGS according to one embodiment of the invention. The module
10 can include a housing 12 comprising a sleeve member 14,
FIG. 1 is an isometric view of an electric machine module 50 a first end cap 16, and a second end cap 18. An electric
according to one embodiment of the invention. machine 20 can be housed within a machine cavity 22 at least
FIG. 2 is a cross-sectional view of a portion of an electric partially defined by the sleeve member 14 and the end caps
machine module according to one embodiment of the inven 16, 18. For example, the sleeve member 14 and the end caps
tion. 16, 18 can be coupled via conventional fasteners 17, or
FIG.3 is a perspective view of a stator assembly according 55 another Suitable coupling method, to enclose at least a portion
to one embodiment of the invention. of the electric machine 20 within the machine cavity 22. In
FIG. 4 is front view of a stator lamination according to one some embodiments, as shown in FIG. 7, the housing 12 can
embodiment of the invention. comprise a substantially cylindrical canister 15 coupled to a
FIG.5 is a perspective view of a conductor according to one single end cap 19. Further, in Some embodiments, the housing
embodiment of the invention. 60 12, including the sleeve member 14 and the end caps 16, 18,
FIG. 6 is a partial cross-sectional view of a portion of an can comprise materials that can generally include thermally
electric machine module according to one embodiment of the conductive properties, such as, but not limited to aluminum or
invention. other metals and materials capable of generally withstanding
FIG. 7 is a cross-sectional view of an electric machine operating temperatures of the electric machine. In some
module according to one embodiment of the invention. 65 embodiments, the housing 12 can be fabricated using differ
FIG. 8 is a cross-sectional view of an electric machine ent methods including casting, molding, extruding, and other
module according to one embodiment of the invention. similar manufacturing methods.
 US 8,803,380 B2
3 4
The electric machine 20 can include a rotor assembly 24, a In some embodiments, the stator winding 36 can comprise
stator assembly 26, including stator end turns 28, and bear a plurality of conductors 44. In some embodiments, the con
ings 30, and can be disposed about a shaft 35. As shown in ductors 44 can comprise a substantially segmented configu
FIG. 2, the stator assembly 26 can substantially circumscribe ration (e.g., a hairpin configuration), as shown in FIGS. 3 and
at least a portion of the rotor assembly 24. In some embodi 5. For example, in some embodiments, at least a portion of the
ments, the rotor assembly 24 can also include a rotor hub 32 conductors 44 can include a turn portion 46 and at least two
or can have a “hub-less' design (not shown). The electric leg portions 48. The turn portion 46 can be disposed between
machine 20 can comprise a substantially conventional con the two leg portions 48 to connect the two leg portions 48.
figuration. For example, an air gap 25 can be defined between which can be substantially parallel. Moreover, in some
a portion of the stator assembly 26 and a portion of the rotor 10 embodiments, the turn portion 46 can comprise a substan
assembly 24. tially “u-shaped configuration, although, in Some embodi
In some embodiments, the electric machine 20 can be ments, the turn portion 46 can comprise a V-shape, a wave
operatively coupled to the module housing 12. For example, shape, a curved shape, and other shapes. Additionally, in
the electric machine 20 can be fit within the housing 12. In some embodiments, as shown in FIG. 5, at least a portion of
some embodiments, the electric machine 20 can be fit within 15 the conductors 44 can comprise a Substantially rectangular
the housing 12 using an interference fit, a shrink fit, other cross section. In some embodiments, at least a portion of the
similar friction-based fit that can at least partially operatively conductors 44 can comprise other cross-sectional shapes,
couple the machine 20 and the housing 12. For example, in Such as Substantially circular, square, hemispherical, regular
some embodiments, the stator assembly 26 can be shrunk fit or irregular polygonal, etc. In some embodiments, the con
into the module housing 12. Further, in some embodiments, ductors 44 can comprise other configurations (e.g., Substan
the fit can at least partially secure the stator assembly 26, and tially non-segmented configuration).
as a result, the electric machine 20, in both axial and circum In some embodiments, as shown in FIG.3, at least a portion
ferential directions. In some embodiments, during operation of the conductors 44 can be positioned substantially within
of the electric machine 20 the fit between the stator assembly the slots 42. For example, in some embodiments, the stator
26 and the module housing 12 can at least partially serve to 25 core 34 can be configured so that the plurality of slots 42 are
transfer torque from the stator assembly 26 to the module Substantially axially arranged. The leg portions 48 can be
housing 12. In some embodiments, the fit can result in a inserted into the slots 42 so that at least some of the leg
generally greater amount of torque retained by the module 10. portions 48 can axially extend through the stator core 34. In
The electric machine 20 can be, without limitation, an Some embodiments, the leg portions 48 can be inserted into
electric motor, such as a hybrid electric motor, an electric 30 neighboring slots 42. For example, the leg portions 48 of a
generator, or a vehicle alternator. In one embodiment, the conductor 44 can be disposed in slots that are distanced
electric machine 20 can be a High Voltage Hairpin (HVH) approximately one magnetic-pole pitch apart (e.g., six slots,
electric motor oran interior permanent magnet electric motor eight slots, etc.). In some embodiments, a plurality of con
for hybrid vehicle applications. ductors 44 can be disposed in the stator core 34 so that at least
Components of the electric machine 20 such as, but not 35 some of the turn portions 46 of the conductors 44 axially
limited to, the rotor assembly 24, the stator assembly 26, and extend from the stator core 34 at a first axial end 50 of the
the stator end turns 28 can generate heat during operation of stator core 34 and at least some of the leg portions 48 axially
the electric machine 20. These components can be cooled to extend from the stator core 34 at a second axial end 52 of the
increase the performance and the lifespan of the electric stator core 34. In some embodiments, at least a portion of the
machine 20. 40 conductor 44 regions that axially extend from the core 34 at
As shown in FIG. 3, in some embodiments, the stator the axial ends 50, 52 can comprise the stator end turns 28.
assembly 26 can comprise a stator core 34 and a stator wind In some embodiments, the conductors 44 can be generally
ing 36 at least partially disposed within a portion of the stator fabricated from a substantially linear conductor 44 that can be
core 34. For example, in some embodiments, the stator core configured and arranged to a shape Substantially similar to the
34 can comprise a plurality of laminations 38. Referring to 45 conductor in FIG. 5. For example, in some embodiments, a
FIG. 4, in some embodiments, the laminations 38 can com machine (not shown) can apply a force (e.g., bend, push, pull,
prise a plurality of substantially radially-oriented teeth 40. In other otherwise actuate) to at least a portion of a conductor 44
some embodiments, as shown in FIG. 3, when at least a to substantially form the turn portion 46 and the two leg
portion of the plurality of laminations 38 are substantially portions 48 of a single conductor 44.
assembled, the teeth 40 can substantially align to define a 50 In some embodiments, at least Some of the leg portions 48
plurality of slots 42 that are configured and arranged to Sup can comprise multiple regions. The leg portions 48 can com
port at least a portion of the stator winding 36. As shown in prise in-slot portions 54, angled portions 56, and connection
FIG.4, in some embodiments, the laminations 38 can include portions 58. In some embodiments, as previously mentioned,
sixty teeth 40, and, as a result, the stator core 28 can include the leg portions 48 can be disposed in the slots 42 and can
sixty slots 42. In other embodiments, the laminations 38 can 55 axially extend from the first end 50 to the second end 52. In
include more or fewer teeth 40, and, accordingly, the stator Some embodiments, after insertion, at least a portion of the leg
core 34 can include more or fewer slots 42. Moreover, in some portions 48 positioned within the slots 42 can comprise the
embodiments, the stator core 34 can comprise an inner perim in-slot portions 58. In some embodiments, in some or all of
eter 41 and an outer perimeter 43. For example, in some the slots 42, the leg portions 48 can be substantially radially
embodiments, the stator core 34 can comprise a Substantially 60 aligned, as shown in FIG.3. In some embodiments, in some or
cylindrical configuration so that the inner and outer perim all of the slots 42, the leg portions 48 can comprise other
eters 41, 43 can comprise inner and outer diameters, respec configurations.
tively. However, in other embodiments, the stator core 34 can In some embodiments, at least some of stator end turns 28
comprise other configurations (e.g., Square, rectangular, extending from the stator core 34 at the second axial end 52
elliptical, regular or irregular polygonal, etc.), and, as a result, 65 can comprise the angled portions 56 and the connection por
the inner and outer perimeters 41, 43 can comprise other tions 58. In some embodiments, after inserting the conductors
dimensions. 44 into the stator core 34, the leg portions 48 extending from
 US 8,803,380 B2
5 6
the stator core 34 at the second axial end 52 can undergo a can remove the heatenergy from the first coolant and then the
twisting process (not shown) that can lead to the formation of first coolant can be recirculated through the coolantjacket 60
the angled portions 56 and the connection portions 58. For for additional cooling.
example, in some embodiments, the twisting process can give Also, in some embodiments, the inner Surface 62 can com
rise to the angled portions 56 at a more axially inward position 5 prise one or more coolant apertures 66 so that the coolant
and the connection portions 58 at a more axially outward jacket 60 can be in fluid communication with the machine
position, as shown in FIGS. 3 and 5. In some embodiments, cavity 22, as shown in FIGS. 2 and 6. In some embodiments,
after the twisting process, the connection portions 58 of at the coolant apertures 66 can be positioned Substantially adja
least a portion of the conductors 44 can be immediately adja cent to the stator end turns 28. For example, in some embodi
cent to connection portions 58 of other conductors 44. As a
10 ments, as the pressurized coolant circulates through the cool
result, the connection portions 58 can be coupled together to ant jacket 60, at least a portion of the coolant can exit the
coolantjacket 60 through the coolant apertures 66 and enter
form one or more stator windings 36. In some embodiments, the machine cavity 22. Also, in Some embodiments, the cool
the connection portions 58 can be coupled via welding, braz ant can contact the stator end turns 28, which can lead to at
ing, soldering, melting, adhesives, or other coupling methods. 15 least partial cooling. After exiting the coolant apertures 66, at
Additionally, in some embodiments, the angled portions 56 least a portion of the coolant can flow through the machine
and the connection portions 58 can extend from the first axial cavity 22 and can contact various module 10 elements, which,
end 50 and can be configured and arranged in a similar man in some embodiments, can lead to at least partial cooling of
ner as Some previously mentioned embodiments. the module 10. Moreover, as shown in FIG. 7, in some
As shown in FIGS. 2, 6, and 7, in some embodiments, the embodiments, the coolant jacket 60 can be substantially or
housing 12 can comprise at least a portion of a coolantjacket completely sealed relative to the machine cavity 22. For
60. For example, as shown in FIGS. 2 and 6, in some embodi example, in Some embodiments, the first coolant can pass
ments, the housing 12 can include an inner Surface 62 and an through the coolantjacket 60 and no material amounts of the
outer surface 64 and the coolantjacket 60 can be positioned first coolant will enter the machine cavity 22 and contact the
substantially between at least a portion the surfaces 62, 64. In 25 electric machine 20.
Some embodiments, the coolant jacket 60 can comprise an According to Some embodiments of the invention, the cool
alternative configuration. For example, as shown in FIG. 7, in ant jacket 60 can include multiple configurations. In some
some embodiments, the outer surface 64 of the housing 12 embodiments, at least a portion of the coolantjacket 60 can
can comprise a portion of the coolantjacket 60 and a coolant extend through portions of the housing 12 (e.g., the sleeve
jacket member 67 can be coupled to the outer surface 64 to 30 member 14) a distance Substantially similar to an axial length
form the coolantjacket 60. In some embodiments, the coolant of the stator assembly 26. For example, an axial length of a
jacket member 67 can comprise a portion of a separate hous portion of the coolantjacket 60 can extend at least the same
ing (e.g., a transmission housing, an engine housing, etc.). distance as the axial length of the stator assembly 26, includ
which can be positioned adjacent to the outer surface 64 to ing the stator end turns 28. In some embodiments, portions of
define the coolantjacket 60. 35 the coolant jacket 60 can extend greater and lesser axial
In some embodiments, the machine cavity 22 can beat least distances, as desired by manufacturers and/or end users for
partially defined by the inner surface 62 (e.g., each of the cooling.
elements of the housing 12 can comprise a portion of the inner In some embodiments, a portion of the coolant jacket 60
surface 62). In some embodiments, the coolantjacket 60 can also can comprise at least one radial extension 68. For
substantially circumscribe at least a portion of the electric 40 example, as shown in FIG. 6, in some embodiments, a region
machine 20. For example, in Some embodiments, the coolant of the inner surface 62 can be radially recessed so that the
jacket 60 can substantially circumscribe at least a portion of radial extension 68 of the coolant jacket 60 can be substan
the outer perimeter 43 of the stator assembly 26 (e.g., the tially adjacent to at least a portion of the stator end turns 28.
stator core 34 and the stator winding 36), including portions In Some embodiments, radial extensions 68 can be positioned
of the stator end turns 28. 45 adjacent to one side of both sides of, or neither sides of the
Further, in some embodiments, the coolant jacket 60 can stator end turns 28. Further, in some embodiments, the cool
contain a first coolant that can comprise transmission fluid, antjacket 60 can comprise radial extensions 68 substantially
ethylene glycol, an ethylene glycol/water mixture, water, oil, continuously adjacent to at least a portion of an outer diameter
motor oil, a gas, a mist, or another Substance. The coolant 70 of at least one set of the stator end turns 28 (i.e., one
jacket 60 can be in fluid communication with a coolant source 50 continuous radial extension 68 around at least a portion of a
(not shown), which can pressurize the coolant prior to or as it circumference of at least one set of the stator end turns 28). In
is being dispersed into the coolantjacket 60 via one or more other embodiments, the coolantjacket 60 can comprise Sub
inlets 87, so that the pressurized coolant can circulate through stantially discrete radial extensions 68 positioned around at
the coolantjacket 60. Additionally, in some embodiments, the least a portion of the outer diameter 70 of at least one set of the
coolantjacket 60 can be in thermal communication with some 55 stator end turns 28. In some embodiments, the housing 12 can
elements of the electric machine 20 (e.g., the stator assembly comprise at least two radial extensions 68. For example, in
26) so that at least a portion of the thermal energy generated Some embodiments, the housing 12 can comprise two halves
by the electric machine 20 can be transferred to the first coupled together in a Substantially axially central location so
coolant (e.g., via conduction, convention, or any other that each half of the housing 12 can comprise a radial exten
energy-transfer method). For example, in some embodi 60 sion 68 and the electric machine 20 can be positioned sub
ments, the coolantjacket 60 can Substantially circumscribe a stantially between the two halves. Moreover, in some
portion of the stator assembly 26 so that as the first coolant embodiments, the radial extension 68 can comprise a radial
circulates through the coolantjacket 60, the first coolant can length substantially similar to other portions of the coolant
receive a portion of the thermal energy rejected by the stator jacket 60.
assembly 26. After circulating through the coolantjacket 60, 65 In Some embodiments, the stator end turns 28 can comprise
the first coolant can be directed to a heat transfer element a generally lesser outer diameter 70 compared to the outer
(e.g., a radiator, a heat exchanger, etc.) (not shown), which diameter 43 of the stator core 34. As a result, a greater dis
 US 8,803,380 B2
7 8
tance can exist between the stator end turns 28 and the cooling and/or the structure which creates a pumping effect can com
jacket 60 in some conventional configurations because at prise different forms. In some embodiments, the rotor assem
least Some conventional coolant jackets 60 comprise agen bly 24 can comprise one or more centrifugal fans 74 coupled
erally linear and/or uniform configuration (e.g., Some con to one or both axial ends of the rotor assembly 24, as shown in
ventional coolantjackets 60 comprise a generally planar con FIG.9. For example, the rotor assembly 24 and the centrifugal
figuration). In some embodiments, the radial extensions 68 of fans 74 can be coupled together so that the centrifugal fans 74
the coolantjacket 60 can enhance module 10 cooling because can rotate synchronously with the rotor assembly 24 during
some of the coolant can circulate relatively closer to the stator electric machine 20 operations. As a result, when the electric
end turns 28, compared to conventional coolant jacket 60 machine 20 is in operation, the centrifugal fans 74 can contact
configurations that lack radial extensions 68. As a result, in 10
the second coolant disposed in the coolant Sump 72 and can
Some embodiments, a distance between the circulating cool pull the second coolant from the coolantsump 72 and disperse
ant and an area rejecting thermal energy (e.g., the stator end or sling the second coolant through portions of the motor
turns 28) can be minimized, which can lead to generally cavity 22 to contact portions of the housing 12 and the electric
increased heat energy transfer.
In some embodiments, the module 10 can comprise at least 15 machine 20 (e.g., the stator end turns 28).
one coolantsump 72. As shown in FIG.7, the coolantsump 72 Additionally, in some embodiments, when the electric
can be in fluid communication with the machine cavity 22. machine 20 is in operation, the moving rotor assembly 24 can
For example, in some embodiments, the coolant Sump 72 can create an area of localized low pressure Substantially at or
be positioned at or near a bottom or lower portion of the near the surface level of the second coolant in the coolant
machine cavity 22. In some embodiments, the coolant Sump Sump 72 (i.e., the Bernoulli Effect can draw least a portion of
72 can be configured and arranged to contain a second cool the second coolant toward the rotor assembly 24). When the
ant, such as oil, vaporizable dielectric fluid, an oil/vaporizable second coolant contacts the rotor assembly 24, the second
dielectric fluid mixture, or a similar substance. For example, coolant can be carried by the rotor assembly 24 and centrifu
in Some embodiments, the second coolant can include prop gally dispersed in a Substantially outward path through por
erties such as, but not limited to: a high dielectric constant, 25 tions the machine cavity 22, thus contacting at least the stator
low electrical conductivity, high thermal conductivity, and an assembly 26, the stator end turns 28, and/or the bearings 30.
ability to lubricate module 10 components. Furthermore, in Some embodiments, the pump or the struc
In some embodiments, during operation of the electric ture which creates a pumping effect can comprise any variety
machine 20, a resting level of the second coolant present of conventional pump 76 or other similar structures that can
within the coolantsump 72 can generally be located below the 30 disperse the second coolant. In some embodiments, the pump
air gap 25 between the rotor and stator assemblies 24, 26. By 76 can be operatively coupled to the housing 12, rotor hub 32,
keeping material and/or significant amounts of the second other portions of the rotor assembly 24, and/or the shaft35, as
coolant out of the air gap 25, coolant shearing, the introduc shown in FIGS. 10 and 11. For example, in some embodi
tion of significant amounts of air, and other complications can ments, the pump 76 can be integrated into at least one portion
be avoided. Moreover, as shown in FIG. 7, the second coolant 35 the housing 12, integrated into the rotor hub 32, or it can be an
can cover and/or coat at least a portion of the stator end turns integral portion of the electric machine 20. In some embodi
28 positioned in the lower portion of the machine cavity 22. ments, the pump 76 can comprise a conventional pump (e.g.,
Additionally, in some embodiments, the second coolant and an electric pump, a gear-type pump, a Vane-type pump, a
the coolant Sump 72 can comprise a portion of a closed-loop centrifugal pump, or other Suitable conventional pumps) that
cooling system. For example, the module 10 can remain 40 can be coupled to the outer surface 64 (as shown in FIG. 10)
Substantially sealed so most of the second coolant remains or remotely located and in fluid communication with at least
within the machine cavity 22 and/or the coolant sump 72, the machine cavity 22 and the coolant sump 72.
unless the housing 12 is disassembled. By way of example only, in some embodiments, the pump
In some embodiments, the coolant Sump 72 can comprise 76 can comprise a conventional gerotor-type pump 76, as
alternative configurations. For example, in some embodi 45 shown in FIG. 11. For example, the gerotor-type pump 76 can
ments, the coolant Sump 72 can comprise structures coupled be operatively coupled to and/or integral with a portion of the
to and/or integral with some portions of the inner surface 62 shaft 35 so that the movement of the shaft 35 during operation
of the housing 12 (i.e., structures extending axially and/or of the machine 20 can drive operation of the pump 76. In some
radially inward from the inner wall 62 of the housing 12 to embodiments, the gerotor-style pump 76 can comprise an
define the coolant sump 72). In some embodiments, the cool 50 inner rotor 78 and an outer rotor 80. In some embodiments,
ant Sump 72 can be a structure operatively coupled a bottom the inner rotor 78 can be operatively coupled to the rotor hub
portion of the housing 12 and in fluid communication with the 32 and/or the shaft35 and the outer rotor 80 can be operatively
machine cavity 22, as shown in FIG. 8. Further, in some coupled to at least one the end caps 16, 18, and 19 (e.g., either
embodiments, the structure can be substantially arcuate to the inner surface 62 or the outer surface 64) or other locations
substantially align with the bottom portion of the outer sur 55 proximal to the module 10. For example, in some embodi
face 64 of the housing 12. In some embodiments, the structure ments, the inner rotor 78 can be operatively coupled to ele
can be substantially integral with a portion of the housing 12. ments of the module 10 so that the inner rotor 78 is generally
Moreover, in some embodiments, the coolant sump 72 can concentric with the rotor hub 32 and/or the shaft 35 and the
comprise a separate reservoir remotely positioned relative to outer rotor 80 is disposed generally radially outward relative
the housing 12 and in fluid communication with the machine 60 to at least a portion of the inner rotor 78. The rotor hub 32
cavity 22. and/or the shaft 35 can move during operation of the electric
In some embodiments, the second coolant can be dispersed machine 20, which can lead to movement of the inner rotor
in different manners through at least a portion the machine 78. The divergence of the inner rotor 78 and the outer rotor 80
cavity 22. In some embodiments, at least a portion of the can create a suction force which draws the second coolant into
second coolant can be drawn from the coolant Sump 72 in a 65 the pump 76, and the merging of the inner rotor 78 and the
generally upward direction by a pump or a structure which outer rotor 80 create pressure which forces the second coolant
creates a pumping effect. In some embodiments, the pump out of the pump 76. As a result, in some embodiments, the
 US 8,803,380 B2
9 10
pump 76 can aid in dispersing of the second coolant through In some embodiments, the coolant Sump 72, the coolant
the module 10, as described in further detail below. channel 82, the shaft channel 86, the rotorchannel 88, and the
As shown in FIG.7, in some embodiments, the housing 12 second coolant can increase thermal energy transfer from at
can include at least one coolant channel 82. In some embodi least the stator end turns 28, the rotor assembly 24, and other
ments, the coolant channel 82 can be generally positioned portions of the electric machine 20 and can create a more
between the inner surface 62 and the outer surface 64. The effective way to sink thermal energy into the coolant jacket
coolant channel 82 can be in fluid communication with the 60. For example, as the second coolant is dispersed through
coolant Sump 72 through a Sump outlet 84 and can extend portions of the machine cavity 22, the second coolant can
through at least a portion of the housing 12, as shown in FIG. receive thermal energy from portions of the electric machine
7. Also, in some embodiments, the sump outlet 84 and the 10 20 (e.g., the stator end turns 28 and the rotor assembly 24)
coolant channel 82 can be positioned at or Substantially adja through forced convection, as previously mentioned. After
cent to one axial end of the coolant Sump 72 and the housing being dispersed through the machine cavity 22, a portion of
12, respectively, as shown in FIG. 7. the second coolant can flow along the inner Surface 62 back
As shown, in FIG. 7, in some embodiments, the coolant towards the coolant Sump 72 (e.g., via gravity). Also, the
channel 82 can be in fluid communication with a shaft chan 15 second coolant can contact the inner Surface 62 and can be
nel 86. For example, a portion of the shaft 35 can comprise the cooled by conducting at least a portion of the thermal energy
shaft channel 86 positioned substantially within the shaft 35 to the housing 12 before it is recycled back into the coolant
and arranged in a generally axial orientation, as shown in FIG. Sump 72. Moreover, in some embodiments, both axial sides of
7. In some embodiments, the shaft channel 86 can extend the the electric machine 12 can be in fluid communication via a
entire axial length of the shaft 35. In other embodiments, the feature in the outer perimeter 43 of the stator core 34 and/or
shaft channel 86 can extend a length less than the axial length the inner surface 62 of the housing 14. For example, the
of the shaft 35, as shown in FIG. 7. feature can comprise a recess positioned on the outer perim
Additionally, in Some embodiments, a portion of the rotor eter 43 and/or the inner surface so that the axial ends 50, 52 of
assembly 24 (e.g., the rotor hub 32) can include a rotor chan the stator assembly 24 can be in fluid communication with
nel 88. In some embodiments, the rotorchannel 88 can extend 25 each other. As a result, the second coolant in the coolant Sump
some or all of the radial length of the rotor assembly 24 (i.e., 72 can be maintained at a lower temperature because the
from an inner diameter of the rotor assembly 24 to an outer heated second coolant can mix with the cooler, unused second
diameter of the rotor assembly 24). In other embodiments, the coolant, which can reduce the overall temperature. At a lower
rotor channel 88 can extenda length less than the radial length temperature, the second coolant can remove additional ther
of the rotor assembly 24. In some embodiments, the rotor 30 mal energy from the electric machine 20 when it is recycled
channel 88 can be in fluid communication with the shaft through the module 10.
channel 86 and the machine cavity 22, as shown in FIG. 7. For In addition, the coolant Sump 72 can be located in the
example, as shown in FIG. 7, at a position adjacent to the machine cavity 22 Substantially adjacent to a portion of the
outer diameter of the rotor assembly 24, the rotor channel 88 coolant jacket 60, as shown in FIG. 7. For example, the
can divide into at least two rotor channels 88, as shown in 35 coolant Sump 72 can be in thermal communication with the
FIG. 7. For example, in some embodiments, the rotor assem coolant jacket 60. As a result, when the second coolant is
bly 24 can comprise one or more coolant outlets 90 that are in recycled back to the coolant sump 72, at least a portion of the
fluid communication with the rotor channels 88. Moreover, thermal energy received from the housing 12 and the electric
the coolant outlets 90 can be configured and arranged so that machine 20 can also be conducted from the second coolant in
a portion of the exiting second coolant can be directed toward 40 the coolant sump 72 through the housing 12 and into the
the stator end turns 28 and other portions of the stator assem coolantjacket 60 and the first coolant. The first coolant can be
bly 26 and the housing 12 for cooling, as shown by the arrows directed out of the coolant jacket 60 to the heat transfer
in FIG. 7. element, which can help remove the thermal energy from the
In some embodiments, the second coolant can be dispersed operating electric machine 20. As a result, the first coolant can
within portions of the module 10 to aid in cooling and lubri 45 be circulated through a heat exchange system and the second
cating module 10 components. In some embodiments, the coolant can remain within the housing 12 and/or the coolant
pump 76 can cause a portion of the second coolant to flow Sump 72 so that the second coolant does not have to pass
from the coolant sump 72, through the sump outlet 84 and into through any other elements (e.g., a transmission housing),
the coolant channel 82 (e.g., the pump 76 can draw at least a which can simplify installation and maintenance of the elec
portion of the second coolant in a generally radially inward 50 tric machine module 10. Also, in some embodiments, the
direction). In some embodiments, the pump 76 can then direct coolantjacket 60 can be localized to a region of the housing
at least a portion of the second coolant to flow through the 12 Substantially adjacent to the coolant Sump 72, as shown in
shaft channel 86 and the rotor channel 88 and enter the FIG. 12. For example, in some embodiments, the coolant
machine cavity 22 via the coolant outlets 90, where the sec jacket 60 can be configured so that it is located adjacent to the
ond coolant can aid in cooling the module 10 components. 55 coolant Sump 72 and does not substantially circumscribe
Furthermore, as the coolant passes through the channels 82. other portions of the module 10 (i.e., the coolant jacket 60
86, and 88, the second coolant can receive at least a portion of serves as a heat exchange element for the coolant Sump 72).
the thermal energy generated by the housing 12, the shaft 35, Furthermore, in some embodiments, the housing 12 can be
and the rotor assembly 24, respectively. configured so that the coolant Sump 72 can Surround at least a
When the second coolant contacts any heat energy-gener 60 portion of the coolantjacket 60 (not shown). For example, as
ating components of the electric machine 20, such as the rotor previously mentioned, in Some embodiments, the coolant
assembly 24, the rotor hub 32, and the stator end turns 28, the Sump 72 can be generally external with machine cavity 22, as
second coolant can provide cooling due to forced convection shown in FIG. 8, and the coolantjacket 60 can be positioned
of thermal energy from the components to the second coolant. substantially internally with respect to the coolant sump 72
Additionally, the second coolant can provide added lubrica 65 (i.e., the coolant Sump 72 and the second coolant can Substan
tion to the bearings 30 and other moving elements of the tially circumscribe and/or surround at least a portion of the
electric machine module 10. coolant jacket 60). As a result of being surrounded by the
 US 8,803,380 B2
11 12
heated second coolant, thermal transfer from the second cool 4. The electric machine module of claim 1, wherein the
ant to the first coolant can be enhanced. second coolant comprises at least one of an oil, a vaporizable
As a result of increased thermal energy transfer from at dielectric fluid, and a combination thereof.
least some portion of the electric machine 20 (e.g., the stator 5. The electric machine module of claim 1, wherein coolant
end turns 28 and the rotor assembly 24) and more effectively 5 jacket is sealed relative to the machine cavity.
sinking thermal energy into the coolantjacket 60, the coolant 6. The electric machine module of claim 1 and further
Sump 72 and/or the coolant channels 82, 86, and 88 with the comprising at least one pump being in fluid communication
Second coolant can increase the continuous performance of
and reduce the operating temperature of the electric machine with the coolant sump.
20, thus increasing both durability and efficiency of the elec 10 pumpThe
7. electric machine module of claim 6, wherein the
comprises a gerotor-type pump operatively coupled to
tric machine 20. In addition, use of the coolant sump 72 the shaft.
and/or the coolant channels 82, 84, and 86 can the reduce the 8. The electric machine module of claim 6, wherein the
work required by the first coolant and the coolantjacket 60 to pump comprises an electric pump.
cool the electric machine 20. As a result, a necessary flow rate 9. The electric machine module of claim 8, wherein the
of the first coolant in the coolant jacket 60 can be reduced, electric pump
15
is coupled to a portion of the housing.
which can increase efficiency of the electric machine module
10 (e.g., by reducing pumping losses to and from the fluid 10. The electric machine module of claim 1, wherein the
Source), and an allowable coolant inlet temperature can be coolantjacket comprises a radial extension.
increased, which can reduce the required size of the heat 11. The electric machine module of claim 1, wherein the
transfer element or eliminate a need for the heat transfer Second coolant is retained within a closed-loop system so that
element completely, thus reducing system costs of the electric the second coolant remains within the coolant sump and the
machine module 10. housing.
It will be appreciated by those skilled in the art that while 12. The electric machine module of claim 1, wherein the
the invention has been described above in connection with electric machine is positioned within the machine cavity so
particular embodiments and examples, the invention is not 25 that the coolantjacket circumscribes at least a portion of the
necessarily so limited, and that numerous other embodi stator assembly.
ments, examples, uses, modifications and departures from the 13. An electric machine module comprising:
embodiments, examples and uses are intended to be encom a housing at least partially defining a machine cavity, the
passed by the claims attached hereto. The entire disclosure of housing further including a coolantjacket;
each patent and publication cited herein is incorporated by 30 a coolant Sump being in fluid communication with the
reference, as if each such patent or publication were individu machine cavity, the coolant Sump capable of containing
ally incorporated by reference herein. Various features and a second coolant different from a first coolant in the
advantages of the invention are set forth in the following coolant jacket, and the coolant sump being in thermal
claims.
The invention claimed is: 35 communication with the coolantjacket;
1. An electric machine module comprising: an electric machine being positioned within the machine
a housing at least partially defining a machine cavity, the cavity and being at least partially enclosed by the hous
housing further including at least a portion of a coolant ing, the electric machine including a stator assembly
jacket capable of containing a first coolant; comprising stator end turns, a rotor assembly being at
a coolant Sump being in fluid communication with the 40 least partially circumscribed by a portion of the stator
machine cavity, the coolant Sump capable of containing assembly, and a shaft being operatively coupled to the
a second coolant different from the first coolant, and the rotor assembly; and
coolant Sump being in thermal communication with the an air gap being defined between a portion of the stator
coolantjacket; assembly and a portion of the rotor assembly, wherein
an electric machine being positioned substantially within 45 the coolant Sump is positioned and sized so that no
the machine cavity and being at least partially enclosed material amounts of the second coolant enter the air gap:
and
by the housing, the electric machine including a stator at least one centrifugal fan being coupled to the rotor
assembly comprising stator end turns, a rotor assembly assembly,
being at least partially circumscribed by a portion of the the centrifugal fan is configured and arranged to disperse
stator assembly, and a shaft being operatively coupled to 50
the rotor assembly; the second coolant through at least a portion of the
at least one coolant channel being disposed through a por machine cavity.
14. The electric machine module of claim 13 and further
tion of the housing, the coolant channel being in fluid comprising at least one coolant channel being disposed
communication with the coolant sump;
at least one shaft channel being disposed through a portion 55 through a portion of the housing, the coolant channel being in
of the shaft, the shaft channel being in fluid communi fluid communication with the coolant sump;
at least one shaft channel being disposed through a portion
cation with the coolant channel; and
at least one rotorchannel being disposed within a portion of of the shaft, the shaft channel being in fluid communi
the rotor assembly, the rotor channel being in fluid com cation with the coolant channel; and
munication with the shaft channel and the machine cav 60 at least one rotorchannel being disposed within a portion of
ity. the rotor assembly, the rotor channel being in fluid com
munication with the shaft channel and the machine cav
2. The electric machine module of claim 1, wherein the ity.
rotor channel is configured and arranged to direct a portion of 15. The electric machine module of claim 14 and further
the second coolant in a generally radially outward direction comprising at least one pump being in fluid communication
toward the stator end turns. 65
3. The electric machine module of claim 1, wherein the first with the coolant sump.
coolant comprises at least one of water and ethylene glycol. ck ck sk sk *k