FIELD OF INVENTION
[0001] The present invention relates to a water pump, and more particularly
the present invention relates to an integrated water pump for thermal management
system used in vehicles.
BACKGROUND OF THE INVENTION
[0002] In automotive sectors thermal management system performs very
important role in vehicles i.e. in commercial vehicles. To control the temperature
10 of the electric motor, inverter, battery and other systems water pump is used to
reduce the temperature. In this period of time the automotive sector is turning to
electrical vehicles. The electrical water pump is used mostly in electrical vehicles
as thermal management system.
[0003] The conventional electrical water pump consists of volute casing with
15 inlet and outlet, screw for connecting housing & rotor casing, shroud, impeller
connected to rotor, rotor casing, oring, stator with windings and terminals, oring,
housing, controller, cover, screw.
[0004] The housing consist of connector and provides support for controller
placement. The rotor consist of impeller, impeller insert, bush flange, hallow shaft,
20 bush, lamina stack, magnets, protecting casing, protecting cover. The impeller is
connected to hallow shaft by connecting to impeller insert, lamina stack is fastened
to hallow shaft, and magnets are inserted in lamina stack of rotor. The housing
includes shaft, the shaft is placed inside hollow shaft. The stator is having lamina
stack with copper windings around it. The stator is placed in the housing. The
25 Controller is connected to the housing.
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[0005] The housing is connected to volute casing with rotor casing in between
them with screw. In between rotor casing and housing the oring is placed and in
between volute casing and housing the oring is placed. Cover are connected to
housing with screw and sealed with the oring.
2
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5
[0006] When the temperature of application is high than limited temperature,
the temperature sensor gives the signal to the controller. The PWM (Pulse-width
modulation) gives the output signal according to the temperature of application. As
PWM signal is given to the motor, the motor start rotating at specified speed.
[0007] While working of the motor because of screws, and orings the
reliability is less. After a while the orings gets degraded, & it causes leakage. It
also etfect on durability of motor. Also, more number of part involved so cost is
high and weight is heavy/bulky.
[0008] To overcome aforementioned drawbacks present in the conventional
10 electric water pump, there is a need of the integrated electric water pump having
high reliability, high durability, less weight, avoid leakage, less cost.
OBJECTS OF THE INVENTION
[0009] The main object of a present invention is to provide an integrated
electric water pump.
15 [00010] The another object of the present invention is to provide an integrated
electric water pump that is highly reliable.
[00011] The another object of the present invention is to provide an integrated
electric water pump that is highly durable.
[00012] The another object of the present invention is to provide an integrated
20 electric water pump that is avoids leakage.
[00013] The another object of the present invention is to provide an integrated
electric water pump that improves efficiency.
[00014] The another object of the present invention is to provide an integrated
electric water pump that is cost efficient.
3
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[00015] The another object of the present invention is to provide provide an
integrated electric water pump with compact design.
SUMMARY OF THE INVENTION
[00016] In an embodiments of present invention an integrated electric water
5 pump, the pump includes a housing ( 40), a volute casing (I 0) having at least one
inlet (170) and atleast one outlet (180), the volute casing (I 0) coupled to housing
( 40) by fastening means, a shaft ( 140) coupled to housing ( 40) by manufacturing
process, a stator assembly (50) coupled to housing ( 40) by fastening means, a rotor
assembly (20), a cover (II 0) coupled to housing ( 40) by fasteners (80), a controller
10 (70) operably coupled to bottom of the housing ( 40)/stator assembly (50) by
fasteners for controlling the speed of pump. The housing ( 40) is integrated with a
rotor casing by manufacturing process to avoid leakage and to improve the
reliability and durability of pump.
[00017] In an embodiments of present invention the manufacturing process like
15 but not limited to injection molding or insert molding or press fitting or snap fitting
or casting or alike.
20
[00018] In an embodiments of present invention the volute casing (1 0) coupled
to housing (40) by fastening means like but not limited to spin welding or press
fitting or alike.
[00019] In an embodiments of present invention the stator assembly (50) having
lamina stack and winding assembly.
ro00201 In an embodiments of present invention the winding assembly includes
a stator teeth, a bobbin, and a coil.
[00021] In an embodiments of present invention the fasteners like but not
25 limited to screws or nut and bolts or alike.
4
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-..._ -:. 1 -~ --._;: ·;- ·; --,_;- ..l.. .1.. -~ ""· :' ~. ..,
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[00022] In an embodiments of present invention the controller (70) mounting
pad (60) coupled to the stator assembly (50) and controller (70) is placed on
controller (70) mounting pad (60) hy pins.
[00023] In an embodiments of present invention the rotor assembly (20) having
5 an impeller (190), a shroud (120), a bush (220) and a magnet (30).
[00024] In an embodiments of present invention the cover ( 11 0) coupled to the
housing (40) by IR (infrared radiation) welding or spin welding or alike.
[00025] In an embodiments of present invention the pump avoids leakage and
improves the reliability and durability.
10 BRIEF DESCRIPTION OF THE DRAWINGS
15
[00026] The accompanying drawings constitute a part of the description and are
used to provide further understanding ofthe present invention. Such accompanying
drawings illustrate the embodiments of the present invention which are used to
describe the principles of the present invention together with the description.
[00027] Fig. 1 shows a cross sectional view of a conventional water pump
disclosed in the prior art;
[00028] Fig. 2 shows a cross sectional view of an integrated electric water pump
in accordance with the preferred embodiment of a present invention.
[00029] Fig: 3 shows an exploded view of an integrated electric water pump in
20 accordance with the preferred embodiment of a present invention.
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[00030] Fig. 4 shows top isometric view of a housing integrated with rotor
casing of an integrated electric water pump in accordance with the preferred
embodiment of a present invention.
5
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.'l . . ·;· ·-._.,... .
[00031] Fig. 5 shows bottom isometric view a housing rotor casmg of an
integrated electric water pump in accordance with the preferred embodiment of a
present invention.
[00032] Fig. 6 shows improvement in reliability, durability and number of child
5 parts of an integrated electric water pump in accordance with the preferred
embodiment of a present invention.
DETAILED DESCRIPTION OF THE INVENTION
[00033] As used in the description herein and throughout the claims that follow,
10 the meaning of "a," "an," and "the" includes plural reference unless the context
clearly dictates otherwise. Also, as used in the description herein, the meaning of
"in" includes "in" and "on" unless the context clearly dictates otherwise.
[00034] If the specification states a component or feature "may", "can", "could",
or "might" be included or have a characteristic, that particular component or feature
15 is not required to be included or have the characteristic.
20
[00035] Exemplary embodiments will now be described more fully hereinafter
with reference to the accompanying drawings, in which exemplary embodiments
are shown. This disclosure may however, be embodied in many different forms and
should not be construed as limited to the embodiments set forth herein.
[00036] The present invention relates to a water pump, and more particularly
the present invention relates to an integrated water pump for thermal management
system used in vehicles.
[00037] Referring, Fig 2, Fig 3, Fig 4, Fig 5 and Fig 6, the integrated electrical
water pump consist of volute casing (I 0) with input and output, the volute casing
25 (10) made up of but not limited to metal or non metal or plastic or thermoplastic
well known in the art, rotor (20) having an impeller ( 190), a shroud (120), the
shroud (120) made up of but not limited to metal or non metal or plastic or
6
thermoplastic, a bush (220) made up of but not limited to metal or non metal or
plastic or thermoset plastic, and a magnet. A washer is placed on the rotor, a shaft
(140) is inserl molded in Lhe huusi11g ( 40), the housing ( 40) made up of but not
limited to metal or non metal or plastic or thermoplastic, the shaft ( 140) made up of
5 but not limited to stainless steel, the housing (40) is integrated with the rotor (20)
casing by but not limited to injection molding or insert molding or press fitting or
snap fitting or casting or alike, and housing ( 40) and the Volute casing (I 0) are
connected to each other by but not limited to spin welding, IR (Infrared Radiation)
welding, or alike.
10
[00038] In present invention the volute casing (1 0) is connected to the housing
(40)by but not limited to spin welding or IR (Infrared Radiation) welding or alike
which will not allow any leakage through it, the rotor (20) assembly is placed on
the shaft (140), the shaft (140) is insert molded with the housing. The washer thrust
15 (130) is placed on the rotor, the washer thrust made up of but not limited to stainless
steel, in between the rotor (20) and the housing.
[00039] The stator is fitted in the housing. The stator is having stator a lamina
stack and a winding assembly. The winding assembly consist of a stator teeth, a
20 bobbin, the bobbin made up of but not limited to metal or non metal or plastic or
thermoplastic, and a coil. The stator terminals (150) are connected to ends of the
coil. The stator teeth's are insert molded with the bobbin. The bobbin is placed on
the stator lamina stack. A controller (70) mounting pad (60) is placed on the stator
assembly (50) having pin like structure for placement of the controller. The
25 controller (70) is placed on the controller (70) mounting pad (60) through the pins
and fitted with the screw to the controller (70) with the controller (70) mounting
pad. The connector (210) main terminals (160) are connectedto the controller (70)
and the rubber seal is placed on the terminals. A cover (11 0) is connected to the
housing ( 40) by but not limited to IR (Infrared Radiation) welding, press fitting,
30 spin welding or alike.
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[00040] The electrical water pump is used in commercial vehicles for thermal
management system at various application such as but not limited to battery
cooling, inverter cooling, DC-DC converter cooling, electric motor cooling, etc.
[00041] In an embodiments of present invention an integrated electric water
5 pump, the pump includes a housing ( 40), a volute casing (1 0) having at least one
inlet (170) and atleast one outlet (180), the volute casing (1 0) coupled to housing
(40) by fastening means, a shaft (140) coupled to housing (40) by manufacturing
process, a stator assembly (50) coupled to housing (40) by fastening means, a rotor
assembly (20), a cover (110) coupled to housing (40) by fasteners (80), a controller
10 (70) operably coupled to bottom of the housing ( 40)/stator assembly (50) by
fasteners for controlling the speed of pump. The housing ( 40) is integrated with a
rotor casing by manufacturing process to avoid leakage and to improve the
reliability and durability of pump.
[00042] In an embodiments of present invention the manufacturing process like
15 but not limited to injection molding or insert molding or press fitting or snap fitting
or casting or alike.
[00043] In an embodiments of present invention the volute casing (1 0) coupled
to housing (40) by fastening means like but not limited to spin welding or press
fitting or alike.
20 [00044] In an embodiments of present invention the stator assembly (50) having
lamina stack and winding assembly.
[00045] In an embodiments of present invention the winding assembly includes
a stator teeth, a bobbin, and a coil.
[00046] In an embodiments of present invention the fasteners like but not
25 limited to screws or nut and bolts or alike.
8
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[00047] In an embodiments of present invention the controller (70) mounting
pad (60) coupled to the stator assembly (50) and controller (70) is placed on
controller (70) mounting pad (60) by pins.
[00048] In an embodiments of present invention the rotor assembly (20) having
5 an impeller ( 190), a shroud (120), a bush (220) and a magnet (30).
[00049] In an embodiments of present invention the cover (II 0) coupled to the
housing (40) by IR (infrared radiation) welding or spin welding or alike.
[00050] Again referring Fig 6: Fig 6a, the bar graph of conventional/prior art
design versus present design, gives improved reliability of present design that
10 conventional. Fig 6b, the bar graph of conventional design versus present design,
gives improved durability of present design that conventional. Fig 6c, the bar graph
of conventional design versus present design, gives less number of child part of
present design that conventional.
15 [00051] In an embodiments of present invention the pump avoids leakage and
improves the reliability and durability.
[00052] An integrated electric water pump (I 00) includes a volute casing (I 0)
made up of but not limited to metal or non metal or plastic or thermoplastic, a rotor
assembly (20), an magnet (30), a housing (40) made up ofbut not limited to metal
20 or non metal or plastic or thermoplastic, a stator assembly (50), a controller
mounting pad (60) made up of but not limited to metal or non metal or plastic or
thermoplastic, a controller (70), a screw fastener (80), a rubber seal (90), a cover
(11 0) made up of but not limited to metal or non metal or plastic or thermoplastic
or alike, a shroud (120) made up of but not limited to metal or non metal or plastic
25 or thermoplastic, a washer thrust (130) made up of stainless steel, a shaft (140)
made up of but not limited to stainless steel, a stator terminals (150), a connector
main terminals (160) made up of but not limited to brass or alike, an inlet (170), an
outlet ( 180), an impeller (190), a connector (21 0), a bush (220) made up of but not
9
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limited to metal or non metal or plastic or thermoplastic or thermoset plastic or
alike.
[00053] The non limiting operational characteristics of an integrated electric
5 water pump (1 00) is explained here, when the temperature of application (e.g. but
not limited to thermal management system of vehicle) is high than limited
temperature, the temperature sensor gives the signal to the controller. Then Pulsewidth
modulation (PWM) (well known in art) of the controller (70) gives the output
signal according to the temperature of application. As PWM signal is given to the
10 motor, the stator produces rotating magnetic field, such that flux links with the rotor
(20) field, then rotor (20) start to rotate at specified speed. Therefore water enters
into the pump by inlet ( 170), it flows from the impeller ( 190) and enters in the rotor
housing ( 40) exits from the outlet (180). As the housing ( 40) and rotor (20) casing
are integrated to each other and the housing (40) is connected to volute casing (1 0)
15 by spin welding rather than oring and screw placements, the leakage is avoided.
This results in· improvement in reliability and durability of the integrated electric
water pump.
[00054] In conventional electrical water pump (eWP) because of orings and
20 screw tightening after a while leakage of water will happen. To neglect that leakage
and to improve the durability and reliability of electric water pump this type of
assembly is designed. And in present invention the number of child parts are less
than a conventional electrical water pump.
[00055] In the above detailed description, reference is made to the
25 accompanying drawings that form a part thereof, however, such description should
not be considered as any limitation of scope of the present invention. The structure
thus conceived in the present description is susceptible of numerous modifications
and variations, all the details may furthermore be replaced with elements having
technical equivalence.
30
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[00056] ADVANTAGES
I. The integrated electric water pump is highly reliable.
2. The integrated electric water pump is highly durable.
3.
5 4.
The integrated electric water pump is having less number of child parts.
Overall performance of integrated electric water pump is improved.
[00057] List of reference numerals:
I. An integrated electric water pump (I 00)
2. A volute casing (10)
10 3. A rotor assembly (20)
4. An magnet (30)
5. A housing ( 40)
6. A stator assembly (50)
7. A controller mounting pad (60)
15 8. A controller (70)
9. A screw fastener (80)
1 0. A rubber seal (90)
1 I. A cover (II 0)
12. A shroud (120)
20 13. A washer thrust (130)
14. A shaft (140)
15. A stator terminals ( 150)
16. A connector main terminals (160)
17. An inlet (170)
25 18. An outlet (180)
30
- - - J - • ~-·
T-~ ~-__ ; ~!-'-~ t; f;\ _:__
19. An impeller (190)
20. A connector (21 0)
21. A bush (220)

CLAIMS
We Claim,
1. An integrated electric water pump, the pump comprises:
a housing ( 40);
a volute casing (1 0) having atleast one inlet ( 170) and atleast one
outlet ( 180), the volute casing ( 1 0) coupled to housing ( 40) by
fastening means;
a shaft (140) coupled to housing (40) by manufacturing process;
a stator assembly (50) coupled to housing (40) by fastening means;
a rotor assembly (20);
a cover ( 11 0) coupled to housing ( 40) by fasteners (80); and
a controller (70) operably coupled to bottom of the housing
( 40)/stator assembly (50) by fasteners for controlling the speed of
pump;
wherein the housing ( 40) is integrated with a rotor casmg by
manufacturing process to avoid leakage and to improve the
reliability and durability of pump;
2. The integrated electric water pump as claimed in claim 1, wherein the
manufacturing process like but not limited to injection molding or insert
molding or press fitting or snap fitting or casting or alike.
3. The integrated electric water pump as claimed in claim 1, wherein the volute
casing (1 0) coupled to housing ( 40) by fastening means like but not limited
to spin welding or press fitting or alike.
25 4. The integrated electric water pump as claimed in claim 1, wherein the stator
30
' ~( ..
assembly (50) having lamina stack and winding assembly.
5. The integrated electric water pump as claimed in claim 1, wherein the
winding assembly includes a stator teeth, a bobbin, and a coil.
6. The integrated electric water pump as claimed in claim 1, wherein the
fasteners like but not limited to screws or nut and bolts or alike.
12
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L '--··
l ,. ··~_::-
5
7. The integrated electric water pump as claimed in claim 1, wherein the
controller (70) mounting pad (60) coupled to the stator assembly (50) and
controller (70) is placed on controller (70) mounting pad (60) by pins.
8. The integrated electric water pump as claimed in claim 1, wherein the rotor
assembly (20) having an impeller ( 190), a shroud ( 120), a bush (220) and a
Magnet (30).
9. The integrated electric water pump as claimed in claim 1, wherein the cover
(11 0) coupled to the housing ( 40) by TR (infrared radiation) welding or spin
welding or alike.
10 l 0. The integrated electric water pump as claimed in claim 1, wherein the pump
avoids leakage and improves the reliability and durability.