Patent ID: 12261494

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

A vehicle, in accordance with a non-limiting example, is indicated generally at10inFIG.1. Vehicle10includes a body12supported on a plurality of wheels16. Two of the plurality of wheels16are steerable. That is, changing a position of two of the plurality of wheels16relative to body12will cause vehicle10to change direction. Body12defines, in part, a passenger compartment20having seats23positioned behind a dashboard26. A steering control30is arranged between seats23and dashboard26. Steering control30is operated to control orientation of the steerable wheel(s). Vehicle10includes an electric motor34connected to a transmission36that provides power to one or more of the plurality of wheels16. A rechargeable energy storage device (RESS)38provides power to electric motor34.

In a non-limiting example, electric motor34takes the form of an axial flux electric motor40having a housing46as shown inFIG.2. Housing46includes an outer surface50and an inner surface52. In a non-limiting example, a stator56is arranged within housing46. Stator56includes an inner support member58that defines a passage60. A plurality of stator segments, one of which is indicated at72, is disposed between inner support member58and inner surface52. As shown inFIGS.3and4, each stator segment72includes a first support frame74and a second support frame76. As will be detailed herein, a stator winding segment80is supported between first support frame74and second support frame76. Stator winding segment80is formed from a plurality of laminations82that are wound by a copper conductor83(FIG.3). Stator winding segment80includes an outer surface section84. A rotor86is axially spaced from second support frame76. Rotor86is supported on a shaft88that passes through passage60and connects with transmission36.

Reference will now follow toFIGS.3-5and with continued reference toFIG.2in describing first support frame74with an understanding that second support frame76includes corresponding structure. First support frame74includes a first axial side94and a second axial side96. Second axial side96is opposite first axial side94. First support frame74also includes a radially inner surface97that is joined with inner support member58and a radially outer surface99. First support frame74is provided with an opening100having a continuous edge102. Opening100extends through first axial side94and second axial side96. Opening100supports a first end (not separately labeled) of stator winding segment80. A second end (also not separately labeled) of stator winding segment80is supported by second support frame76.

A gap106exists between outer surface section84of stator winding segment80and continuous edge102defining opening100. Gap106may be continuous, or include a series of non-contiguous sections. Gap106reduces thermal transfer efficiency between stator winding segment80and first support frame74. As such, gap106could lead to thermal excursions (i.e., areas of stator winding segment having a higher temperature than surrounding portions) on stator winding segment80that may reduce operational efficiency. In an effort to reduce thermal excursion, first support frame74, in accordance with a non-limiting example, includes a thermal bridging system108that takes the form of thermal interface material (TIM)110extending across gap106connecting stator winding segment80and first support frame74. Additional TIM (not shown) may be provided between stator winding segment80and second support frame76.

In a non-limiting example, TIM110is arranged on first axial side94bridging stator winding segment80and first support frame74. In another non-limiting example, TIM110is arranged on second axial side96bridging stator winding segment80and first support frame74. In still a further non-limiting example, TIM110extends between stator winding segment80and first support frame74from first axial side94to second axial side96. In a non-limiting example, TIM110may take the form of a solid material such as a sheet. In another non-limiting example, TIM110may take the form of a fluid that hardens after a prescribed period or when exposed to an accelerant. Regardless of the form, TIM110forms a bridge that transports heat uniformly from each stator winding segment radially outwardly through each stator segment. Additional TIM120may be arranged between radially outer surface99of first support frame74and inner surface52of housing46.

The terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The term “or” means “and/or” unless clearly indicated otherwise by context. Reference throughout the specification to “an aspect”, means that a particular element (e.g., feature, structure, step, or characteristic) described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects.

When an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this disclosure belongs.

While the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from its scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within the scope thereof