Electromechanical device

Abstract

An electromechanical device comprising a stator 1, a rotor 2, and one or more TEG portions 3, 19 positioned to accept heat from at least one of the stator and the rotor.

Description

Technical Field

[0001] The present invention relates to electromechanical devices such as electric motors and generators. Background Art

[0002] An electric motor is a device that consumes electrical power and produces shaft power. A generator is a device that consumes shaft power and produces electrical power. Some devices are capable of operating as either an electric motor or a generator.

[0003] Electric motors have long been used in vehicles to power auxiliary equipment such as cooling fans, and their use for moving vehicles is becoming increasingly popular. Vehicles that include an electric motor to supplement the internal combustion engine are called "hybrid vehicles," while vehicles that rely solely on the electric motor for power are called "electric vehicles."

[0004] Some vehicles employ a generator to dissipate axle power from the vehicle's road-engaging wheels and thereby slow the vehicle (or adjust the vehicle's speed when descending.) This is known as "regenerative braking."

[0005] The efficiency of typical electromechanical devices is not 100%. Some power is lost in the conversion between electrical power and shaft power. The inventors have recognized that it would be useful to recapture at least some of this lost power.

[0006] In view of the foregoing, the present invention aims to provide improvements or at least alternatives in and for electromechanical devices.

[0007] It is not admitted that any of the information in this patent specification forms part of the common general knowledge or that a person skilled in the art could reasonably be expected to have known or understood such information, considered it relevant or used it in any way before the priority date. Summary of the Invention

[0008] The present inventors have recognized that existing electromechanical devices lose energy as heat, which can be recaptured using one or more thermoelectric generators (TEGs), and that efficiencies can be achieved by positioning TEG portions to accept heat from specific portions of the electromechanical device.

[0009] A TEG is a solid-state device that generates electricity when exposed to a temperature difference. A typical TEG is a thin plate or mesh-like device with two major sides corresponding to a heat receiving side and a heat dissipating side, respectively.

[0010] Generally speaking, there are three different types of TEG cells. The first type includes ceramic substrate rigid TEG cells that are constructed electrically in series and thermally in parallel between each of the P and N semiconductor pairs.

[0011] The second type has flexible properties and is constructed as a rigid TEG in series with flexible electrodes and substrates that allow it to bend in only one direction (ignoring a small degree of "TEG cell stack-up flex" in other directions, which is typically less than 20 degrees). The inventors recognized that uniaxial flexible TEG cells are unable to bend in the second direction because they are constructed in series and thermally in parallel, which results in a lack of mechanical strength in the second direction and breakage of the flexible TEG cells through the flexible substrate and electrodes.

[0012] The third type is biaxially flexible. The bending rotation in the second direction is greater than 300 degrees. These biaxial TEG cells are each constructed as a cluster of paired P and N semiconductors. For example, Group A of P and N semiconductors can be bent along one axis, and Group B of P and N semiconductors can be bent along the other axis, allowing them to operate independently within a biaxial TEG cell. Groups A and B are not connected together during their power generation process and independently combine to supply power.

[0013] One aspect of the present invention provides an electromechanical device, the electromechanical device comprising:

[0014] stator;

[0015] rotor; and

[0016] One or more TEG portions are positioned to accept heat from at least one of the stator and the rotor.

[0017] Preferably, the housing encloses the stator, the rotor and the one or more TEG portions.Most preferably, the electromechanical device includes a cooling path within the housing to carry cooling air over at least one of the one or more TEG portions.

[0018] Optionally, the stator includes a winding and the one or more TEG sections include a winding-powered TEG section located on a portion of the winding. The winding-powered TEG section can be wrapped around the portion of the winding. The winding-powered TEG section is preferably a flexible TEG section, or more preferably a biaxially flexible TEG section. Optionally, a body of glue is bonded to each of the winding-powered TEG section and the portion of the winding.

[0019] Optionally, the stator includes a lamination stack and the one or more TEG sections include a lamination-powered TEG section located on a portion of the lamination stack. The lamination-powered TEG section may be wrapped around the portion of the lamination stack. The lamination-powered TEG section is preferably flexible. Preferably, the adhesive body is bonded to the lamination-powered TEG section and the laminations of the lamination stack.

[0020] Optionally, the one or more TEG portions include a rotor powered TEG portion positioned on a portion of the rotor, preferably on an interior portion of the rotor. Preferably, the rotor powered TEG portion is flexible, for example biaxially flexible. A glue body may be bonded to each of the rotor powered TEG portion and the rotor.

[0021] Preferably, at least one of the one or more TEG portions is flexible, such as biaxially flexible.

[0022] The electromechanical device may be an electric motor for moving the vehicle and / or a generator for regeneratively braking the vehicle.

[0023] Another aspect of the present invention provides an electromechanical device, the electromechanical device comprising:

[0024] stator;

[0025] rotor; and

[0026] one or more TEG portions positioned to receive heat from at least one of the stator and the rotor;

[0027] The stator includes

[0028] lamination stacking; and

[0029] head windings, each comprising a ring around an end of the lamination stack; and

[0030] The one or more TEG sections include one or more winding powered TEG sections; and

[0031] The one or more winding powered TEG portions are biaxially flexible.

[0032] Another aspect of the present invention provides an electromechanical device, the electromechanical device comprising:

[0033] stator;

[0034] rotor; and

[0035] one or more TEG portions positioned to receive heat from at least one of the stator and the rotor;

[0036] The stator includes

[0037] lamination stacking; and

[0038] head windings, each comprising a respective loop around a respective end of the lamination stack; and

[0039] The one or more TEG portions include one or more winding-powered TEG portions covering at least a majority of the head winding.

[0040] Preferably, the one or more TEG portions cover at least 90% of the head winding.

[0041] Optionally, at least one respective one of the head windings has a respective inner retainer extending around at least a majority of an interior of the respective head winding and urging the TEG portion outwardly against the respective head winding.

[0042] In one embodiment, the respective inner retainer is elastically deformed inwardly to urge the TEG portion outwardly against the respective head winding.

[0043] Optionally, at least one respective one of the head windings has a respective outer retainer extending around at least a majority of the exterior of the respective head winding and urging the TEG portion inwardly against the respective head winding.

[0044] In one embodiment, the respective outer retainer is elastically deformed outwardly to urge the TEG portion inwardly against the respective head winding.

[0045] The electromechanical device may comprise a flow path that conveys fluid to cool the portion of the TEG powered by the one or more windings. Preferably, the flow paths cool the head windings in parallel with each other.

[0046] Another aspect of the present invention provides an electromechanical device, the electromechanical device comprising:

[0047] stator;

[0048] rotor;

[0049] one or more TEG portions positioned to accept heat from at least one of the stator and the rotor; and

[0050] a flow path that conveys a fluid to cool a portion of the TEG powered by the one or more windings;

[0051] The stator includes

[0052] lamination stacking; and

[0053] head windings, the head windings each comprising a ring around an end of the lamination stack;

[0054] The one or more TEG sections include one or more winding powered TEG sections; and

[0055] The flow paths cool the head winding in parallel with one another.

[0056] Another aspect of the present invention provides an electromechanical device, the electromechanical device comprising:

[0057] a stator comprising a lamination stack;

[0058] rotor;

[0059] one or more TEG portions positioned to receive heat from at least one of the stator and the rotor;

[0060] a flow path that conveys fluid to cool the one or more TEG portions; and

[0061] A cooling system supplies cooled fluid to the flow path.

[0062] The cooling system may comprise a heat pump. Optionally, the cooling system comprises an air conditioner that cools the interior of the vehicle.

[0063] Another aspect of the present invention provides an electromechanical device, the electromechanical device comprising:

[0064] stator;

[0065] rotor; and

[0066] one or more TEG portions positioned to receive heat from at least one of the stator and the rotor;

[0067] wherein the stator comprises a lamination stack; and

[0068] The one or more TEG portions include one or more laminate powered TEG portions covering at least a majority of an exterior of the laminate stack.

[0069] Preferably, the one or more laminate powered TEG portions cover at least 90% of the exterior of the laminate stack.

[0070] Another aspect of the present invention provides a vehicle. The vehicle may be an electric vehicle. Alternatively, it may be a hybrid vehicle. Preferably, it is a road vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] Figure 1a is a perspective view of the stator carrying the TEG;

[0072] Figure 1b is a cross-sectional view showing a sector portion of a stator carrying a TEG;

[0073] Figure 2 It is a half-section view of another stator carrying TEG;

[0074] Figure 3 is a perspective view of another stator carrying TEG;

[0075] Figure 4a 、 Figure 4b and Figure 4c A flexible TEG is schematically illustrated;

[0076] Figure 5a and Figure 5b Two TEG pieces connected to each other via a plug and a socket are illustrated;

[0077] Figure 6a 、 Figure 6b and Figure 6c Two TEG pieces connected to each other via a flexible connection are illustrated;

[0078] Figure 7a and Figure 7b illustrates two TEG pieces interconnected by a flexibly mounted plug and socket;

[0079] Figure 8a TEG is exemplified;

[0080] Figure 8b is shown as assembled with Figure 8a A cross-sectional view of a sector-shaped portion of a TEG rotor;

[0081] Figure 8c is shown in combination with the axis Figure 8b Cross-sectional view of the rotor and TEG;

[0082] Figure 9 is a cross-sectional view showing a sector-shaped portion of an electric motor;

[0083] Figure 10a is a cross-sectional view showing a sector portion of a stator, TEG, and housing assembly;

[0084] Figure 10b yes Figure 10a An exploded view of the combination;

[0085] Figure 11 is a schematic plan view of a hybrid vehicle;

[0086] Figure 12a A tiled one-piece TEG is illustrated;

[0087] Figure 12b illustrates a one-piece TEG formed to fit over a head winding;

[0088] Figure 12c is held in place by restraints Figure 12b A perspective view of a TEG component;

[0089] Figure 13a is a cross-sectional view of a semi-annular TEG piece assembled to a head winding;

[0090] Figure 13b Illustrated in combination with a restraint Figure 13a A part of the TEG piece;

[0091] Figure 13c is a perspective view of a portion of an alternative semi-annular TEG member;

[0092] Figure 14a is a perspective view of a TEG component with alternative head winding power supply;

[0093] Figure 14b yes Figure 14a A plan view of the TEG member in its closed configuration;

[0094] Figure 15 It is a perspective cross-sectional view of the TEG component that supplies energy to the rotor;

[0095] Figure 16a is an exploded view of the motor / generator unit;

[0096] Figure 16b yes Figure 16a a cross-sectional view of a motor / generator unit; and

[0097] Figure 17 is a half-section view of an alternative motor / generator unit. DETAILED DESCRIPTION

[0098] FIG1 shows a stator 1 equipped with a TEG 3. The stator 1 comprises a lamination stack 1a in the form of a short, approximately cylindrical tube. The stack 1a is made of individual laminations, each having a thickness of, for example, approximately 0.7 mm and a generally annular form. Each lamination typically comprises a main body of steel and a surface coating, by which the steel is electrically insulated from adjacent laminations.

[0099] Typically, the interior of each lamination is interrupted by a circular array of cutouts. The cutouts are aligned relative to each other so that they define longitudinal channels. These channels within the lamination stack carry the windings.

[0100] Typical windings are formed from enamel-coated copper and are repeatedly wound so that the strands follow an internal channel and turn at the end of the channel to return along another internal channel. Typically, the channels within the lamination stack are lined with plastic to protect the windings therein.

[0101] The portions of the winding exposed at each end of the stack together form a ring around the end of the lamination stack, the ring typically having a nearly annular form facing axially outwards. This end is known as the "head winding".

[0102] Figure 2 An alternative form of stator 1 ' is illustrated comprising a lamination stack 1a and exposed winding portions 5' and surrounded by TEGs 3'. The stator 1 is a tube having a length similar to its width, whereas the stator 1 ' is a shorter disc-like form.

[0103] Preferably, the TEG 3 is part of a set of TEG sections that cover at least a substantial portion of the exterior of the lamination stack 1a and / or at least a substantial portion of the windings, on the outside of the rotor (or inside in the case of an external rotor motor) and would otherwise be exposed. Preferably, the mechanically separate TEG sections are spaced apart around the stator 1.

[0104] This example of a lamination stack 1a includes a cylindrical outer portion. The TEG 3 is flexible and includes a portion 3a that conforms to the cylindrical outer portion and a head winding portion 3b that takes an approximately annular form to wrap around the head winding. The TEG 3 includes an intermediate portion 3c that interconnects the portions 3a, 3b. Preferably, the TEG 3 includes a uniform arrangement of P semiconductor and N semiconductor and two electrodes that is flexible to bend biaxially and is attached to a flexible substrate. The flexible substrate may be made of perovskite, polymer plastic or silicon-based material. Optionally, elements of graphene and / or graphite are embedded in the substrate to improve thermal conductivity into the TEG unit. Flexible TEGs are preferred because they conform to the curvature of existing motor designs without requiring modification of the lamination profile or requiring shaped mounting features to occupy the space between the cylindrical lamination stack and the planar TEG surface.

[0105] Experiments by the inventors have shown that placing the TEG directly on the lamination stack 1a is more effective. Optionally, the TEG is assembled with the aid of thermally conductive adhesive without intervening components, whereby a single body of adhesive is adhered to each of the lamination stack 1a and the TEG portion 3a. The adhesive secures the TEG to the lamination stack and conforms to the surfaces of the lamination stack and the TEG portion for efficient heat transfer. Other thermally conductive, conformable materials, such as thermal paste or graphite, may be used, for example, in combination with other attachment methods.

[0106] The TEG 3 takes the form of a simple strip of material that is "biaxially flexible," able to flex about two axes to conform to a toroidal or spherical surface, and thereby to conform closely to the shape of the head winding.

[0107] In this example, there may be some accumulation of material in the transition region 3c. Figure 3 In another variation of the system illustrated in FIG4C , the middle portion 3c has a pair of cutouts 7 extending inwardly from each edge to enable the TEG portion to conform more closely to the stack 1a and the head portion. Figure 4b and Figure 4cAs suggested in , the cutout 7 connects the parts 3a, 3b to each other via a narrow neck of flexible material, whereby the parts 3a, 3b can twist and move freely relative to each other.

[0108] A thin base plate is preferred. Optionally, the base plate may be reinforced with reinforcements 8, such as edge reinforcements 8a extending along each of the two long edges of the strip, transverse reinforcements 8b extending across the width of the strip at spaced locations along the strip to divide the strip into approximately square sections, and possibly also edge reinforcements 8c along the edges of the slots 7.

[0109] Figures 5a to 7b An alternative embodiment includes a separable TEG portion that can be associated with and interconnected to TEG portions 3a, 3b. Interconnecting different TEG portions allows different types of TEG materials to be combined. For example, it may be more cost-effective to manufacture the laminate-powered TEG portion 9a from a material that is flexible only about a single axis and connect it to the biaxially flexible winding-powered portion 9b. Figure 5a 、 Figure 5b Plugs 11a are illustrated as being mounted directly on the respective TEG portions. The plugs 11a and the receptacles 11b are examples of connectors that can cooperate with each other to electrically connect the TEG portions to each other. Figures 6a to 7b Other connection arrangements are illustrated. Figures 6a to 6c An example is illustrated in which a lamination stack powered TEG portion 13a is connected to a winding powered portion 13b by a flexible connection arrangement 15. The flexible connection arrangement may take any convenient form, for example it may comprise flexible conductors soldered to terminals of the TEG portions 13a, 13b.

[0110] Figure 7a and Figure 7b A variation is illustrated in which the TEG parts are connectable to each other via a flexibly mounted plug 17 a and a receptacle 17 b flexibly mounted and cooperating with the plug 17 a .

[0111] Figures 8a to 8c A rotor powered TEG portion 19 is illustrated, comprising a center portion 19a that can be mounted to cover the cylindrical interior of a rotor 21. End portions 19b are shaped to wrap over the ends of the rotor 21. In this example, the combination 19, 21 is sized to define an air gap 25 around the shaft 21.

[0112] Figure 9A sector of an electric motor is illustrated comprising a stator / TEG combination 1, 3 surrounding a rotor / TEG combination 19, 20 and a shaft 23. This assembly of parts is then enclosed in a housing 27 to define an air gap 29. In this example, a cooling fan 31 is fixed to rotate with the shaft 23 and drives cooling air along the air gaps 25, 29 to flow over the TEGs 19, 3. The housing is preferably an aluminum housing.

[0113] In this way, the TEG is positioned to accept heat directly from the stator and rotor, both of which may be well above 100°C (eg, above 150°C) and reject the heat to cooling air, which may well be ambient air or conditioned air.

[0114] Exposing the TEG portion directly to the hot components of the motor improves the performance of the TEG and provides a more controlled environment. Specifically, the cooling air flow can be more carefully controlled, and the housing 27 serves to protect the TEG from damage.

[0115] Preferred variations of the housing prevent objects with a diameter greater than 1 mm from reaching the conductors. It is also preferred that the housing protect the electrical components from splashing water; for example, it is preferred that the housing have an IP rating of at least IP44. Most preferably, the housing is at least dustproof (IP5X) or more preferably dust-tight (IP6X). Higher levels of water protection are preferred, such as protection from water jets (IPX5) or more preferably protection from at least powerful water jets (IPX6). In the context of ventilation systems, these higher levels can be achieved with the aid of filters and / or water traps.

[0116] Figure 9 The motor is illustrated as including an air gap 29 having an annular cross-section. A fan 31 creates a pressure gradient to cause air to flow axially through the air gap 29. Another variation may include a second fan on the other end of the shaft 23 to draw air through the air gap. Fanless variations are also possible; for example, the motor may be connected to a cooling system that delivers a flow of cooling air to the motor.

[0117] Figure 10a 、 Figure 10b Another variant is illustrated in which the housing 27 is penetrated by cooling holes and a pressure gradient is established whereby the cooling air CA travels radially inwards through these cooling holes and impinges on the TEG portion 3 mounted on the stator 1 .

[0118] Figure 11A hybrid vehicle 33 is schematically illustrated and includes a combustion engine 35, drive wheels 37, a mechanical transmission 39 for transmitting shaft power from the combustion engine 35 to the drive wheels 37, an electromechanical unit (EMU) 41 along the transmission 39, and a battery 43 electrically connected to the EMU 41. The EMU is equipped with a TEG to recover energy.

[0119] The transmission 39 is capable of transmitting shaft power in either direction between the EMU 41 and the motor 35 on the one hand and the drive wheels 37 on the other hand.

[0120] The EMU has both a motor mode and a generator mode. In some operating modes (e.g., when the vehicle is in slow-moving traffic), the EMU 41 can be the sole source of shaft power for the drive wheels. At other times, the engine 35 and the EMU 41 can simultaneously supply shaft power. At other times, the EMU 41 can be operated to draw power from the drive wheels 37 for regenerative braking and / or from the combustion engine 35.

[0121] Some variations of the electromechanical devices disclosed herein can be effectively applied in other contexts, such as in vehicles other than road vehicles and in non-vehicle-related contexts. For example, some generator variations can be effectively employed to improve the efficiency of wind turbines. Other generator variations can be driven by other shaft power sources, such as an internal combustion engine. Such generator variations can potentially be incorporated into a vehicle context and separated from any regenerative braking. For example, such combustion engine / generator combinations can be added to electric vehicles to extend their range.

[0122] Figure 12a An alternative TEG piece 100 is illustrated, comprising a biaxial flexible portion 101 mechanically and electrically connected to a uniaxial flexible portion 103. Biaxial flexible portion 101 is mounted over the head winding. Portions 101 and 103 have mutually distinct sets of P and N semiconductors that operate independently to generate power. Optionally, piece 100 is double-ended, including a respective biaxial flexible portion at each end to be wound over each head winding.

[0123] Figure 12b An alternative TEG piece 100a is illustrated that includes a dual-axis flexible portion 101a and a single-axis flexible portion 103a that are mechanically connected but electrically isolated from each other.

[0124] While thermally conductive glue is one option for attaching the TEG, the inventors have recognized that such glue may limit maintainability. For example, a TEG bonded to the head winding would make it difficult to replace the TEG without rewinding the motor.

[0125] Figure 12cIllustrated are preferred restraints 105a, 105b, 105c by which the plurality of TEG pieces 101a arranged around the motor are held in place.

[0126] The TEG 100a comprises an inner hook 107 located radially inside the head winding. The hook 107 is axially open, inside the TEG part 101a, and carries a holder 105a.

[0127] Retainer 105a is a resilient member similar to an inner circlip. It rotates almost 360 degrees around the motor and elastically deforms inward to axially pass through the head winding. When released, resilient element 105a springs outward to push the winding-powered portion 101a against the head winding. Constraint 105b is another resilient member and is similar to an outer circlip. It is deployed, placed, and then released to spring inward and thereby push the winding-powered portion 101a against the head winding. Constraint 105c is a relatively large constraint similar to constraint 105b and pushes the lamination-powered portion of TEG 103a radially inward against the cylindrical exterior of the lamination stack.

[0128] Figure 13a The TEG element 109 with alternative winding power supply is shown. Figure 12c The winding-powered piece 109 has an approximately semi-annular form to fit over the head winding 111 - that is, the piece 109 is a ring with a radial profile that is open to receive the head winding. The radial profile of the piece 109 is an approximately U-shaped channel profile.

[0129] The winding-powered piece 109 (and the corresponding set of sections 100a) completely covers the head winding 111 to better capture heat from the head winding. The TEG piece 109 includes a radially inner hook 107a that is turned radially inward to open axially away from the stator laminations and is accessible from the outside of the head winding-powered section. This orientation enables the retainer 105 to be placed after the winding-powered section 109 has been placed on the head winding 111.

[0130] Figure 13c An alternative semi-toroidal winding powered TEG piece 109a is illustrated including a hook 107b that is configured in accordance with Figure 12c The hook 107 opens within the radial profile of the TEG portion that the winding powers.

[0131] Figure 14a 、 14bAnother TEG powered winding portion 109b is illustrated that includes an array of biaxially flexible TEG portions surrounding a central opening 113. The TEG piece 109b includes a resilient element 115 attached to the inner periphery of the TEG portion. The resilient element 115 incorporates mutually complementary releasable fastening features (in this case hook and loop) that cooperate to hold the element 115 in place. Figure 14b 109b can then be manipulated to place the elastic element 115 within the head winding and adjacent to the lamination stack. Once in this position, the hook and loop (or other releasable fastening arrangement) can be released to allow the element 115 to spring outwardly according to the retainer 105a.

[0132] These circlip-like elastic elements provide a convenient means for holding the TEG portion in place and promoting efficient heat transfer while maintaining maintainability. The circlip-like restraint is merely one example of a concept. In another embodiment, the restraint may take the form of a closed loop that elastically expands (or contracts) and releases to push the TEG portion inward (or outward) against the heat source. For example, restraint 105b may be replaced by a long extension spring whose ends are connected to each other.

[0133] In another embodiment, the elastic elements 105a, 105b, 105c can be replaced by other means for radial urging. For example, the restraint 105b can be replaced by a restraint in the form of a band similar to a hose clamp and a screw that can be tightened to hold the TEG portion of the winding power supply against the head winding.

[0134] Other releasable means of mounting the TEG portion are possible, for example a spring, hook, strap, clamp, ring, belt and / or tab may be employed. Optionally, the TEG portion may include an opening (such as a reinforced opening) through which the TEG portion is fastened in place. Figure 15 A TEG portion 117 is illustrated including an opening 119 that fits to a hook 121 of the rotor to tie the portion 117 in place.

[0135] Figure 16a and Figure 16b Illustrated is a motor / generator unit 123 incorporating a cooling cap 125 and a cooling housing 127 surrounding a stator / TEG combination 129 .

[0136] The housing 127 defines a narrow air gap through which a turbulent flow of air moves to cool the TEG. Optionally, a coolant other than air may be employed, such as water.

[0137] Unit 123 also includes a rotor / TEG combination 131 ( Figure 16b ) cooling device.

[0138] Each cooling cap 125 comprises a ring whose radial profile is a channel profile to receive an end portion 127a of a corresponding annular form of the housing 127. The radial profile of the end portion 127a is also a channel profile to fit over the head winding of the assembly 129.

[0139] End portion 127a is penetrated by a set of openings 133. When assembled, cap 125 and housing 127 together define an annular plenum 135. Inlet 13 supplies cooling air to plenum 135, and openings 133 distribute the air to head winding 129a of combination 129. Thus, combination 127a, 125 constitutes a flow distributor for distributing cooling fluid in parallel to radially separated portions of the head winding for more uniform and efficient cooling of the head winding. Other flow distribution plenums and more general other flow distribution arrangements are possible.

[0140] Each end of unit 123 has a similar flow distribution arrangement, whereby each of the two ends (or more specifically, each of the two head windings) is cooled in parallel. In this way, each head winding receives "fresh" cooling air that has not yet been heated by the heat from the other head winding. This results in more uniform and efficient cooling. The air exits housing 127 via one or more outlets 139 that open radially outward from the lamination stack of assembly 129.

[0141] In this example, air also exits radially inwardly via annular outlet 141 near the end of the lamination stack.

[0142] This example of the concept includes a hollow shaft 143 extending through the center of the rotor. The exterior of the shaft is spaced inwardly from the portion of the TEG carried within the rotor to define an air gap. An inlet arrangement 145 (in this case comprising a pair of opposing radial openings) connects the interior of the shaft 143 to the air gap surrounding the shaft 143. Air is drawn from the shaft, in this case via each end of the shaft 143, whereby air exiting inwardly from outlet 141 flows radially inwardly, passes over the ends of the rotor, and then flows axially inwardly toward the inlet arrangement 145, through the air gap, and cools the internal rotor-powered TEG.

[0143] In a preferred embodiment, the housings 125, 127 extend radially inward to sealingly engage the shaft 143 and define the axial outer boundary of a flow path along which coolant flowing from the head windings flows radially inward en route to the air gap surrounding the shaft 143. This allows the housings 125, 127 to be pressurized. Testing has shown that pressurization results in improved cooling and is preferred regardless of the configuration of the cooling housing.

[0144] The illustrated cooling system divides the heated coolant between outlets 139 around the perimeter of unit 123 and an outlet at the end of shaft 143. In a preferred embodiment, a portion of the heated coolant (e.g., the coolant carried by shaft 143) is routed to cool other components (e.g., other components in the vehicle's drivetrain).

[0145] In this preferred example, a majority (e.g., at least 90%) of the exterior of the stator-rotor combination is covered in the TEG portion. Also, in the illustrated implementation, a majority (e.g., at least 90%) of the exterior of the stator / rotor / TEG combination is immersed in cooling air. Immersing the exterior in moving cooling air (as opposed to exposing the TEG portion to hot, stagnant air) improves efficiency.

[0146] In some implementations, the coolant can be ambient air. In other scenarios, it may be advantageous to cool the air. This may require a heat pump (most preferably, a heat pump from an air conditioner already in place) to cool the space intended for the user (such as cooling the cabin of a vehicle). For example, inlet 137 may be supplied by fluid drawn from the vehicle's air conditioner.

[0147] Other cooling fluids are possible. Figure 17 Schematically illustrated is a half-section view of a water-jacketed stator / rotor combination 147 that includes a water jacket 149 equipped with a pair of inlets 149a and a set of outlets 149b arranged around the exterior of the unit 147. In the context of a hydroelectric power station (e.g., a pumped hydroelectric power station), water may make a single pass through the water jacket 149. In other scenarios, a closed-loop system may be convenient, for example, water (or other coolant) may exit outlets 149b and be cooled by a heat pump before returning to inlet 149a.

[0148] The term "comprise" and its grammatical variations have a meaning determined by the context in which they appear. Therefore, unless the context so requires, the term should not be interpreted exhaustively. Similarly, unless the context so requires, the article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.

[0149] The present invention is not limited to the examples disclosed herein. Instead, the present invention is defined by the claims.

Claims

1. An electromechanical device, comprising: stator; rotor; and one or more TEG sections positioned to accept heat from at least one of the stator and the rotor; The stator comprises Lamination stacking; and head windings, each comprising a ring around an end of the lamination stack; and The one or more TEG sections include one or more winding powered TEG sections; and The one or more winding powered TEG portions are biaxially flexible. 2 . The electromechanical device of claim 1 , wherein the one or more TEG portions cover at least a majority of the head winding.

3. An electromechanical device, comprising: stator; rotor; and one or more TEG sections positioned to accept heat from at least one of the stator and the rotor; The stator comprises Lamination stacking; and head windings, the head windings each comprising a respective loop around a respective end of the lamination stack; and The one or more TEG portions include one or more winding-powered TEG portions covering at least a majority of the head winding.

4. The electromechanical device of claim 3, wherein the one or more winding-powered TEG portions are flexible.

5. An electromechanical device according to claim 2, 3 or 4, wherein the one or more TEG portions cover at least 90% of the head winding.

6. An electromechanical device according to any one of claims 1 to 5, wherein at least one respective one of the head windings has a respective inner retainer that extends around at least a majority of the interior of the respective head winding and urges the TEG portion outwardly against the respective head winding. 7 . The electromechanical device of claim 6 , wherein the respective inner retainer is elastically deformed inwardly to urge the TEG portion outwardly against the respective head winding.

8. An electromechanical device according to any one of claims 1 to 7, wherein at least one respective one of the head windings has a respective outer retainer that extends around at least a majority of the exterior of the respective head winding and urges the TEG portion inwardly against the respective head winding.

9. The electromechanical device of claim 8, wherein the respective outer retainer is elastically deformed outwardly to urge the TEG portion inwardly against the respective head winding.

10. An electromechanical device according to any one of claims 1 to 9, comprising a flow path that conveys fluid to cool the portion of the TEG powered by the one or more windings.

11. The electromechanical device of claim 10, wherein the flow paths cool the head windings in parallel with each other.

12. An electromechanical device, comprising: stator; rotor; one or more TEG sections positioned to accept heat from at least one of the stator and the rotor; and a flow path that conveys a fluid to cool a portion of the TEG powered by the one or more windings; The stator comprises Lamination stacking; and head windings, the head windings each comprising a ring around an end of the lamination stack; The one or more TEG sections include one or more winding powered TEG sections; and The flow paths cool the head winding in parallel with one another.

13. An electromechanical device according to claim 11 or 12, comprising a cooling system supplying cooled fluid to the flow path.

14. An electromechanical device, comprising: a stator comprising a lamination stack; rotor; one or more TEG sections positioned to accept heat from at least one of the stator and the rotor; a flow path that conveys a fluid to cool the one or more TEG portions; and A cooling system supplies cooled fluid to the flow path.

15. An electromechanical device according to claim 13 or 14, wherein the cooling system comprises a heat pump.

16. The electromechanical device of claim 15, wherein the cooling system comprises an air conditioner that cools an interior of a vehicle.

17. An electromechanical device according to any one of claims 1 to 16, wherein the one or more TEG sections comprise one or more laminate powered TEG sections covering at least a majority of an exterior of the laminate stack.

18. An electromechanical device, comprising: stator; rotor; and one or more TEG sections positioned to accept heat from at least one of the stator and the rotor; wherein the stator comprises a lamination stack; and The one or more TEG portions include one or more laminate powered TEG portions covering at least a majority of an exterior of the laminate stack.

19. An electromechanical device according to claim 13 or 14, wherein the one or more laminate-powered TEG portions cover at least 90% of an exterior of the laminate stack.

20. An electromechanical device according to any one of claims 1 to 18, wherein the one or more TEG sections comprises a rotor powered TEG section positioned on a portion of the rotor.

21. The electromechanical device of claim 10, wherein the rotor powered TEG portion is on an interior portion of the rotor.

22. An electromechanical device according to claim 20 or 21, wherein the rotor powered TEG portion is flexible.

23. An electromechanical device according to any one of claims 1 to 22, comprising a housing enclosing the stator, the rotor and the one or more TEG portions.

24. An electromechanical device according to any one of claims 1 to 23, being an electric motor for moving a vehicle or the vehicle.

25. An electromechanical device according to any one of claims 1 to 24, being a generator for regenerative braking of a vehicle or the vehicle.

26. A vehicle comprising an electromechanical device according to claim 24 or 25.

Images