	US 12,206,306 B2
	Electrical machine, in particular for a vehicle with a cooling channel for cooling stator windings
Roberto Almeida E Silva, Stuttgart (DE); Bernd Blankenbach, Boeblingen (DE); Terry Cox, Swinford (GB); Philip Grabherr, Stuttgart (DE); Niklas Kull, Stuttgart (DE); Tim Male, Telford (GB); Peter Pisek, Leitring (AT); Peter Sever, Murska Sobota (SI); Josef Sonntag, Nuertingen (DE); and Martin Williams, Northkampton (GB)
Assigned to MAHLE INTERNATIONAL GMBH, (DE)
Filed by Mahle International GmbH, Stuttgart (DE)
Filed on Nov. 17, 2019, as Appl. No. 16/686,206.
Claims priority of application No. 102018219817.9 (DE), filed on Nov. 19, 2018.
Prior Publication US 2020/0161916 A1, May 21, 2020
Int. Cl. H02K 3/24 (2006.01); H02K 9/197 (2006.01); H02K 9/22 (2006.01)

CPC H02K 3/24 (2013.01) [H02K 9/197 (2013.01); H02K 9/227 (2021.01)]

26 Claims

1. An electrical machine comprising:

a rotor that is rotatable about an axis of rotation, by way of which an axial direction of the electrical machine is defined, and a stator that has electrically conductive stator windings; and

at least one cooling channel through which a coolant is flowable for cooling the stator windings;

wherein the stator has stator teeth that extend along the axial direction, are arranged spaced apart from one another along a circumferential direction of the rotor, and bear the stator windings;

wherein the at least one cooling channel and at least one stator winding are arranged in at least one intermediate space that is formed between two stator teeth adjacent to each other in the circumferential direction;

wherein a first plastic for transferring heat from the at least one stator winding to the at least one cooling channel is arranged on surface sections of the two adjacent stator teeth delimiting the intermediate space;

wherein a second plastic forms at least one phase insulation arranged in the intermediate space and that divides the intermediate space into a radially inner subspace and a radially outer subspace and forms filler portions;

wherein a third plastic surrounds an entire perimeter of the at least one cooling channel in a cross section perpendicular to the axial direction and is in contact with at least one of the first plastic and the second plastic;

wherein the at least one phase insulation formed by the second plastic is arranged between a plurality of first conductor elements of the stator winding disposed in the radially inner subspace and a plurality of second conductor elements of the stator winding disposed in the radially outer subspace;

wherein the filler portions of the second plastic are disposed between each of adjacent first conductor elements of the plurality of first conductor elements and each of adjacent second conductor elements of the plurality of second conductor elements;

wherein the intermediate space including the radially inner subspace and the radially outer subspace is provided substantially without gaps via the second plastic so as to be free from air pockets; and

wherein the at least one phase insulation has a radial thickness greater than that of the filler portions.