Enhanced cooling system for electromagnetic components

Abstract

Various embodiments of this disclosure include an apparatus and system comprising a cooling tube having a proximal end having a first opening and a distal end having a second opening. The cooling tube includes an intermediate portion extending between the proximal end and the distal end. The apparatus includes an interface component disposed on an external interface of the intermediate portion and at least partially enclosing the cooling tube, the interface component being made of an electrically insulating and thermally conductive material. The interface component is in abutment contact with one or more thermally conductive or heating elements of an electromechanical device.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 586,923, filed September 29, 2023, entitled “Enhanced Cooling System for Electromagnetic Components,” the entire disclosure of which is incorporated herein by reference for all purposes. Background Technology

[0003] In various high-performance motors, cooling tubes are used in stator slots to cool windings, coils, and other components. Cooling tubes are typically a more aggressive cooling mechanism than conventional air cooling technology.

[0004] Despite some progress in the field of high-performance motors, there is still a need in the field for improved methods and systems for cooling components of high-performance motors. Summary of the Invention

[0005] This disclosure generally relates to an electrically insulating and thermally conductive interface component for use in cooling pipes in a cooling system. More specifically, embodiments of the invention provide a system that uses one or more interface materials to enhance the thermal interface between conductive cooling system components, electrical windings, and electrode steel or alloy cores. Embodiments of the invention are applicable to a wide variety of power systems.

[0006] Various embodiments of this disclosure describe an interface component characterized by high thermal conductivity and low electrical conductivity. In various embodiments of this disclosure, the interface component, comprising an electrically insulating material, is configured around a cylindrical cooling tube to provide electrical insulation to the cooling tube. In some embodiments, the interface component provides contact on all sides of the cooling tube. In other embodiments, the cooling tube is additionally encapsulated in the interface component in an electrically insulating manner. The interface component may be a thermally conductive but non-conductive ceramic, such as boron nitride, silicon carbide, etc.

[0007] Many benefits are achieved through this disclosure compared to conventional techniques. Embodiments of the invention optimize cooling by improving the thermal conductivity of the cooling tubes in machinery through electrical insulation and by providing interface components according to the various techniques described herein. These and other embodiments of the present disclosure, along with their many advantages and features, are described in more detail below in conjunction with the accompanying drawings. Attached Figure Description

[0008] Figure 1A A cross-sectional view of a motor stator including interface components according to an embodiment of the present disclosure is shown.

[0009] Figure 1B A perspective view of an interface component according to an embodiment of the present disclosure is shown.

[0010] Figure 2 A cross-sectional view of a motor stator including an interface component according to an embodiment of the present disclosure is shown, the interface component being sized to be mounted in a slot using a gasket.

[0011] Figure 3 A cross-sectional view of a motor stator including an interface component according to an embodiment of the present disclosure is shown, the interface component being sized to be mounted in a slot.

[0012] Figure 4 A cross-sectional view of a motor stator including an interface component according to an embodiment of the present disclosure is shown, the motor stator including the interface component deposited at an appropriate location within a groove.

[0013] Figure 5A The following are illustrated “slotless” arrangements without stacked sheets according to various embodiments of the present disclosure.

[0014] Figure 5B A "semi-slotless" arrangement with a partially stacked structure is shown according to various embodiments of the present disclosure.

[0015] Figure 6A A cross-sectional view of an interface component applied between a cold plate and an electrical conductor, according to various embodiments of the present disclosure, is shown.

[0016] Figure 6B A cross-sectional view of an interface component applied between a cold plate and a magnetic core according to various embodiments of the present disclosure is shown.

[0017] Figure 6C Cross-sectional views of interface components applied between a cold plate and an electrical conductor, and between a cold plate and a magnetic core, according to various embodiments of the present disclosure, are shown.

[0018] Figure 7 Exemplary applications of the enhanced cooling embodiments described herein according to various embodiments of this disclosure are shown. Detailed Implementation

[0019] This disclosure generally relates to an electrically insulating and thermally conductive interface component for use in cooling pipes in a cooling system. More specifically, embodiments of the invention provide a system that uses one or more interface materials to enhance the thermal interface between conductive cooling system components, electrical windings, and electrode steel or alloy cores. Embodiments of the invention are applicable to a wide variety of power systems.

[0020] The enhanced cooling systems for electromagnetic components described herein significantly improve the thermal performance (e.g., power density) of these components, including but not limited to motors, generators, transformers, and inductors. Advanced materials such as boron nitride offer high thermal conductivity relative to conventional electrical insulating materials and act as electrical insulators. Therefore, various embodiments of this disclosure utilize boron nitride as an enhanced thermal interface between conductive cooling system components, electrical windings, and electrode steel or alloy cores. This advanced material interface can replace conventional electrical insulating materials (which have historically been poor thermal conductors), thereby significantly increasing the thermal conductivity of the cooling system loop. The various embodiments described herein increase thermal conductivity by at least 30°C at operating current. Thus, regardless of the heat source, the interface components absorb heat from the system for cooling.

[0021] Conventional cooling tubes can be formed into a roughly square shape along their length. Inspecting cooling tubes formed in this way is time-consuming and expensive. The forming process is relatively complex and imprecise. Non-perfectly square cooling tubes cannot achieve sufficient thermal contact on all sides, resulting in reduced thermal conductivity. Any electrical conductivity through the cooling tube degrades its performance. In some conventional techniques, an electrically insulating groove liner is used between the cooling tube and the coil, further reducing direct contact for cooling and creating a thermal barrier that adversely affects cooling performance.

[0022] The enhanced cooling system for electromagnetic components described herein contrasts with typical electromagnetic cooling schemes, including forced or free convection air cooling, liquid cooling via integral backplate or cooling pipes, or direct cooling of conductors (e.g., non-conductive fluids within or around coil conductors). This also contrasts with less standard cooling arrangements in which cooling pipes are preferably located within the electromagnetic component, placing them very close to heat sources (e.g., electrical conductors) and is insulated by electrical insulating materials (e.g., plastics, aramids, polyimides, or braided fiber products) exhibiting poor thermal conductivity. The enhanced cooling system, manufactured with a boron nitride interface component configuration, has demonstrated performance improvements on multiple stators, all exhibiting enhanced thermal properties. Other embodiments of this disclosure may include additional homogeneous or composite materials that provide high thermal conductivity relative to conventional electrical insulating materials while also acting as electrical insulators. Various manufacturing techniques can be employed, such as machining, casting, 3D printing, and flame spray deposition.

[0023] According to the various embodiments described herein, embodiments of the present invention can replace or reinforce existing conventional insulating materials, such as "groove liners," "glass tapes," "mica tapes," etc., with unconventional materials exhibiting low thermal conductivity and high resistivity (e.g., boron nitride, boron carbide, diamond, etc.). For example, these thermally conductive and high-resistivity materials minimize insulation thickness and maximize the cross-sectional area of ​​the coil conductor, thereby minimizing Joule losses in the machine such that Joule loss ∝ 1 / copper cross-sectional area. In one exemplary embodiment, the thermally conductive and high-resistivity material is boron nitride, which has a resistivity greater than 10 12 The volume resistivity is between 10 kV / mm and 230 kV / mm, and the thermal conductivity is between 10 W / (mK) and 230 W / (mK). In contrast, the thermal conductivity of conventional insulating materials ranges from 0.1 W / mK to 1.0 W / mK.

[0024] Figure 1A A cross-sectional view of a motor stator 108 including an interface component 102 according to one embodiment of the present disclosure is shown. According to various embodiments, the interface component 102 may comprise an electrically insulating and thermally conductive material, such as boron nitride, boron carbide, diamond, silicon carbide, or any combination thereof. In an exemplary embodiment, the interface component 102 primarily comprises boron nitride. Figure 1A An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C).

[0025] According to various embodiments, interface component 102 may come into contact with one or more heat-conducting or heating elements of motor stator 108 or other electromechanical devices. Such heat-conducting or heating elements may include, for example, heat sources 114 or stacks 110 of laminations. According to various embodiments, interface component 102 may include multiple portions, or interface component 102 may be a single integral part. Interface component 102 may include a first portion 103 and a second portion 105, wherein the first portion 103 and the second portion 105 are mirror images of each other. In various embodiments, interface component 102 includes multiple portions, such as at least three portions, at least four portions, etc. The first portion 103 may include a first interface 107, and the second portion 105 may include a second interface 109. According to at least some embodiments, the first interface 107 and the second interface 109 may be mirror images of each other. Figure 1A As shown, the first interface 107 and the second interface 109 are curved, such that the first interface 107 and the second interface 109 contact at least a portion of the cooling pipe 104. For example, the first portion 103 has a width W. P1 And the second part 105 has a width W P2And the gap 111 between the first part 103 and the second part 105 has a width W. G According to various embodiments, W P1 It can be greater than, less than or equal to W P2 The slot 106 of the motor stator 108 (which includes a first portion 103 and a second portion 105) may have a width W. S W S =W P1 +W P2 +W G Gap 111 ensures sufficient physical contact between the cooling pipe 104 and the first portion 103 and the second portion 105 of the interface component 102. Gap 111 ensures that the interface component 102 is fully wedged into the groove 106 to provide sufficient thermal contact. In an exemplary embodiment, if the motor stator 108 is subsequently vacuum pressure impregnated (VPI), gap 111 may be filled with resin during the VPI process performed on the completed motor stator assembly.

[0026] In some embodiments, the first interface 107 and the second interface 109 contact the entire exterior of the cooling pipe 104, and the groove 106 has a width W. S W S =W P1 +W P2 For example, in at least some embodiments, the sum of the length of the first interface 107 and the length of the second interface 109 is equal to the circumference of the cooling pipe 104. The cooling pipe 104 may include a proximal end having a first opening (e.g., in the direction outward from the page) and a distal end having a second opening (e.g., in the direction inward toward the page). The cooling pipe 104 may include an intermediate portion extending between the proximal and distal ends.

[0027] According to various embodiments, and as Figure 1A As shown, the first interface 107 and the second interface 109 are curved, such that the first interface 107 and the second interface 109 contact at least a portion of the cooling pipe 104. The cooling pipe used throughout this disclosure may include stainless steel. The cooling pipe 104 may include a conductive material, such as stainless steel, steel, copper, copper-nickel alloy, or any combination thereof. Figure 1A In the embodiment shown, cooling fluid flows into the drawing and passes through cooling pipe 104.

[0028] In this embodiment, a typical electric motor arrangement is shown. The motor stator 108 includes a stack 110 of laminations on each side of the slot 106. Current conducted through a heat source 114 (e.g., coils, etc.) generates a flux in the stack 110 of laminations, which interacts with a rotor (e.g., the rotating portion of the motor) to generate torque on the rotor (not shown). To remove heat generated in the motor stator 108, a cooling pipe 104 may be included, and the cooling pipe 104 is electrically isolated from the stack 110 of laminations and the heat source 114. In various embodiments, a first portion 103 and a second portion 105 of the interface component 102 are arranged between an insulator 116 and a push rod 118, the insulator 116 being arranged on the heat source 114. The push rod 118 is a mechanical feature for holding various components (e.g., the cooling pipe 104, the first portion 103 and the second portion 105 of the interface component, etc.) in the slot 106. According to some embodiments, a groove (not shown) is present in the stack 110 of the laminations, and a corresponding groove (not shown) of the top rod 118 slides into this groove during assembly. The high resistivity of boron nitride allows the cooling assembly to be located in the slot 106 (e.g., such as a stator slot) along with the heat source 114 without the need for additional electrical insulation material. Such additional electrical insulation material could reduce the overall thermal conductivity of the cooling system. Boron nitride is available in different grades and is easy to process. This allows for different geometries of slot width and / or tube size. Any length or number of slots can be used. The cooling tube 104 can be made of any material compatible with the cooling medium.

[0029] In various embodiments, the interface component 102 can be used in non-motor generator applications, such as for stationary electromagnetic components. In particular, for transformers with back iron members that maintain cooling, the interface component 102 can be applied to cold plates and transformer laminations to improve thermal conductivity.

[0030] Figure 1B A perspective view of an interface component according to an embodiment of the present disclosure is shown. Figure 1B A motor stator 108 with a stator 130 having a plurality of slots is shown. Each slot 106 may include an interface component 102 encapsulating a cooling tube 104. According to various embodiments, the interface component 102 may include an electrically insulating and thermally conductive material, such as boron nitride, boron carbide, diamond, silicon carbide, or any combination thereof. In an exemplary embodiment, the interface component 102 primarily includes boron nitride. Figure 1B An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C).

[0031] According to various embodiments, interface component 102 may come into contact with one or more heat-conducting or heating elements of motor stator 108 or other electromechanical devices. Such heat-conducting or heating elements may include, for example, heat source 114 or a stack of laminations 110. According to various embodiments, interface component 102 may include multiple portions, or interface component 102 may be a single integral part.

[0032] Cooling pipe 104 may include a proximal end 120 having a first opening 121 and a distal end 122 having a second opening 123. Cooling pipe 104 may include an intermediate portion 150 (enclosed by interface component 102) extending between the proximal end 120 and the distal end 122. Cooling pipes used throughout this disclosure may include stainless steel. Cooling pipe 104 may include conductive materials such as stainless steel, steel, copper, copper-nickel alloys, or any combination thereof. Figure 1B In the embodiment shown, cooling fluid flows through cooling pipe 104 between first opening 121 and second opening 123.

[0033] Figure 2 A cross-sectional view of a motor stator 208 including an interface component 202 according to one embodiment of the present disclosure is shown. The interface component is sized to be mounted within a slot 206 using a gasket 220. According to various embodiments, the interface component 202 may comprise an electrically insulating and thermally conductive material, such as boron nitride, boron carbide, diamond, silicon carbide, or any combination thereof. In an exemplary embodiment, the interface component 202 primarily comprises boron nitride. Figure 2 An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C). The high resistivity of boron nitride allows the cooling assembly to be located in the slot 206 (e.g., such as a stator slot) along with the heat source 214 without the need for additional electrical insulation material. The additional electrical insulation material can reduce the overall thermal conductivity of the cooling system. Boron nitride is available in different grades and is easy to process. This allows for different geometries of slot width and / or tube size. Any length or number of slots can be used. The cooling tube 204 can be made of any material compatible with the cooling medium.

[0034] According to various embodiments, interface component 202 may include multiple parts, or interface component 202 may be a single integral component. Interface component 202 may include a first part 203 and a second part 205, wherein the first part 203 and the second part 205 are mirror images of each other. In various embodiments, interface component 202 includes multiple parts, such as at least three parts, at least four parts, etc. The first part 203 may include a first interface 207, and the second part 205 may include a second interface 209. According to at least some embodiments, the first interface 207 and the second interface 209 may be mirror images of each other. Figure 2 As shown, the first interface 207 and the second interface 209 are curved, such that the first interface 207 and the second interface 209 contact at least a portion of the cooling pipe 204.

[0035] According to some embodiments, the interface component 202 is too small, resulting in a clearance fit within the groove 206. The gasket 220 can be used to ensure a tight fit of the interface component 202 covering the cooling pipe 204 in various geometries, such as... Figure 2 As shown. The gasket 220 can be used to wedge between the cooling assembly (e.g., interface component 202 and cooling pipe 204) and the wall 217 of the groove 206, as shown. Figure 2 As shown. Gasket 220 may include any combination of materials. In one exemplary embodiment, gasket 220 may be a G-11 glass epoxy laminate, as it does not significantly reduce thermal performance.

[0036] In this embodiment, the first portion 203 has a width W P1 And the second part 205 has a width W P2 And the gap 211 between the first part 203 and the second part 205 has a width W G The gap 211 ensures sufficient physical contact between the cooling pipe 204 and the first portion 203 and the second portion 205 of the interface component 202. The gap 211 also ensures that the interface component 202 is fully wedged into the slot 206 to provide sufficient thermal contact. The slot 206 of the motor stator 208 (which includes the first portion 203 and the second portion 205) may have a width W. S In this embodiment, W P1 Not equal to W P2 And W S ≠W P1 +W P2 +W G Therefore, a gasket 220 can be provided to assemble the interface component 202 within the slot 206. The gasket 220 may have a width W. SH The W SH Supplement the width of the first part 203 and the second part 205 so that W S =WP1 +W P2 +W G +W SH In various embodiments, one or more gaskets may be used, such as a first gasket adjacent to the first portion 203 and a second gasket adjacent to the second portion 205.

[0037] According to various embodiments, and as Figure 2 As shown, the first interface 207 and the second interface 209 are curved, such that the first interface 207 and the second interface 209 contact at least a portion of the cooling pipe 204. The cooling pipe used throughout this disclosure may include stainless steel. The cooling pipe 204 may include a conductive material, such as stainless steel, steel, copper, copper-nickel alloy, or any combination thereof. Figure 2 In the embodiment shown, cooling fluid flows into the drawing and passes through cooling pipe 204.

[0038] In this embodiment, a typical electric motor arrangement is shown. The motor stator 208 includes a stack 210 of laminations on each side of the slot 206. Current conducted through a heat source 214 (e.g., coils, etc.) generates a flux in the stack 210 of laminations, which interacts with the rotor, thereby generating torque on the rotor (not shown). To remove heat generated in the motor stator 208, a cooling pipe 204 may be included, and the cooling pipe 104 is electrically isolated from the stack 210 of laminations and the heat source 214. In various embodiments, a first portion 203 and a second portion 205 of the interface component 202 are arranged between an insulator 216 and a push rod 218, the insulator 116 being arranged on the heat source 214. The push rod 218 is a mechanical feature for holding various components (e.g., the cooling pipe 204, the first portion 203 and the second portion 205 of the interface component, etc.) in the slot 106. According to some embodiments, a groove (not shown) exists in the stack 210 of the laminations, and a corresponding groove (not shown) of the top rod 218 slides into this groove during assembly. The high resistivity of boron nitride allows the cooling assembly to be located in the slot 206 (e.g., such as a stator slot) along with the heat source 214 without the need for additional electrical insulation material. Such additional electrical insulation material can reduce the overall thermal conductivity of the cooling system. Boron nitride is available in different grades and is easy to process. This allows for different geometries of slot width and / or tube size. Any length or number of slots can be used. The cooling tube 204 can be made of any material compatible with the cooling medium.

[0039] In various embodiments, the interface component 202 can be used in non-motor generator applications, such as for stationary electromagnetic components. In particular, for transformers with back iron members that maintain cooling, the interface component 202 can be applied to cold plates and transformer laminations to improve thermal conductivity.

[0040] Figure 3A cross-sectional view of a motor stator 308 including an interface component 302 according to one embodiment of the present disclosure is shown. The interface component 302 is initially oversized, i.e., the sum of the widths of the first portion 303 and the second portion 305 is greater than the width of the slot 306, and then the width is reduced, for example, by grinding and polishing, to fit within the slot 306. According to various embodiments, the interface component 302 may include an electrically insulating and thermally conductive material, such as boron nitride, silicon carbide, boron carbide, diamond, or any combination thereof. In an exemplary embodiment, the interface component 302 primarily includes boron nitride. Figure 3 An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C).

[0041] According to various embodiments, interface component 302 may include multiple parts, or interface component 302 may be a single integral part. Interface component 302 may include a first part 303 and a second part 305, wherein the first part 303 and the second part 305 are mirror images of each other. In various embodiments, interface component 302 includes multiple parts, such as at least three parts, at least four parts, etc. The first part 303 may include a first interface 307, and the second part 305 may include a second interface 309. According to at least some embodiments, the first interface 307 and the second interface 309 may be mirror images of each other. Figure 3 As shown, the first interface 307 and the second interface 309 are curved, such that the first interface 307 and the second interface 309 contact at least a portion of the cooling pipe 304. For example, the first portion 303 has a width W. P1 And the second part 305 has a width W P2 And the gap 311 between the first part 303 and the second part 305 has a width W G The gap 311 ensures sufficient physical contact between the cooling pipe 304 and the first portion 303 and the second portion 305 of the interface component 302. The gap 311 ensures that the interface component 302 is fully wedged into the groove 306 to provide sufficient thermal contact.

[0042] According to various embodiments, W P1 It can be greater than, less than or equal to W P2 The slot 306 of the motor stator 308 (which includes a first portion 303 and a second portion 305) may have a width W. S .

[0043] In various embodiments, the dimensions of the assembly formed by the interface component 302 and the cooling pipe 304 can be designed to be relatively large, such that its dimensions are proportional to the width W of the groove 306. SAn interference fit is formed. During assembly, the interface component 302 can be ground or polished to form a tight fit with the groove 306. For example, W can be reduced. P1 and / or W P2 This makes W S =W P1 +W P2 +W G .

[0044] In some embodiments, the first interface 107 and the second interface 109 contact the entire exterior of the cooling pipe 104, and the groove 106 has a width W. S Therefore, W can be reduced. P1 and / or W P2 This makes W S =W P1 +W P2 .

[0045] According to various embodiments, and as Figure 3 As shown, the first interface 307 and the second interface 309 are curved, such that the first interface 107 and the second interface 309 contact at least a portion of the cooling pipe 304. The cooling pipe used throughout this disclosure may include stainless steel. The cooling pipe 304 may include a conductive material, such as stainless steel, steel, copper, copper-nickel alloys, or any combination thereof. Figure 3 In the embodiment shown, cooling fluid flows into the drawing and passes through cooling pipe 304.

[0046] In this embodiment, a typical electric motor arrangement is shown. The motor stator 308 includes a stack 310 of laminations on each side of the slot 306. Current conducted through a heat source 314 (e.g., coils, etc.) generates a flux in the stack 310 of laminations, which interacts with the rotor, thereby generating torque on the rotor (not shown). To remove heat generated in the motor stator 308, a cooling pipe 304 may be included, and the cooling pipe 104 is electrically isolated from the stack 310 of laminations and the heat source 314. In various embodiments, a first portion 303 and a second portion 305 of the interface component 302 are arranged between an insulator 316 and a push rod 318, the insulator 316 being arranged on the heat source 314. The push rod 318 is a mechanical feature for holding various components (e.g., the cooling pipe 304, the first portion 303 and the second portion 305 of the interface component, etc.) in the slot 306. According to some embodiments, a groove (not shown) exists in the stack 310 of the laminations, and a corresponding groove (not shown) of the top rod 318 slides into this groove during assembly. The high resistivity of boron nitride allows the cooling assembly to be located in the slot 306 (e.g., such as a stator slot) along with the heat source 314 without the need for additional electrical insulation material. Such additional electrical insulation material can reduce the overall thermal conductivity of the cooling system. Boron nitride is available in different grades and is easy to process. This allows for different geometries of slot width and / or tube size. Any length or number of slots can be used. The cooling tube 304 can be made of any material compatible with the cooling medium.

[0047] In various embodiments, interface component 302 can be used in non-motor generator applications, such as for stationary electromagnetic components. In particular, for transformers with back iron members that maintain cooling, interface component 302 can be applied to cold plates and transformer laminations to improve thermal conductivity.

[0048] Figure 4 A cross-sectional view of a motor stator 408 according to an embodiment of the present disclosure is shown, including an interface component 402 formed or deposited in place. The material of the interface component 402 can be formed or deposited using various advanced manufacturing techniques, such as additive manufacturing, casting, hot pressing, sintering, or flame spraying, to eliminate gaps between loose components and enhance contact resistance between the components to minimize their interaction. According to various embodiments, the interface component 402 may comprise an electrically insulating and thermally conductive material, such as boron nitride, boron carbide, diamond, silicon carbide, or any combination thereof. In an exemplary embodiment, the interface component 402 primarily comprises boron nitride. Figure 4 An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C).

[0049] According to various embodiments, the interface component 402 can be deposited as a single integral part in the trench 406. For example... Figure 4 As shown, interface component 402 is configured such that it encloses cooling pipe 404 within groove 406. The cooling pipe used throughout this disclosure may include stainless steel. Cooling pipe 304 may include conductive materials such as stainless steel, steel, copper, copper-nickel alloys, or any combination thereof. Figure 4 In the illustrated embodiment, cooling fluid flows into the drawing and passes through cooling pipe 404. In at least some embodiments, the slot 406 of the motor stator 408 may have a width W. S The width W S The width W of interface component 402 is equal to IS .

[0050] In this embodiment, a typical electric motor arrangement is shown. The motor stator 408 includes a stack 410 of laminations on each side of the slot 406. Current conducted through a heat source 414 (e.g., coils, etc.) generates a flux in the stack 410 of laminations, which interacts with the rotor, thereby generating torque on the rotor (not shown). To remove heat generated in the motor stator 408, a cooling pipe 404 may be included, and the cooling pipe 404 is electrically isolated from the stack 410 of laminations and the heat source 414. In various embodiments, an interface component 402 is arranged between an insulator 416 and a push rod 418, the insulator 416 being arranged on the heat source 414. The push rod 418 is a mechanical feature for holding various components (e.g., the cooling pipe 404 and the interface component 402, etc.) in the slot 406. According to some embodiments, a groove (not shown) is present in the stack 410 of laminations, and a corresponding groove (not shown) of the push rod 418 slides into this groove during assembly. The high resistivity of boron nitride allows the cooling assembly to be located in the slot 406 (e.g., a stator slot) along with the heat source 414 without the need for additional electrical insulation material. Such additional electrical insulation material would reduce the overall thermal conductivity of the cooling system. Boron nitride is available in different grades and is easy to process. This allows for different geometries of slot width and / or tube size. Any length or number of slots can be used. The cooling tube 404 can be made of any material compatible with the cooling medium.

[0051] In various embodiments, the interface component 402 (e.g., a heterogeneous, composite crystalline, or metallic (e.g., boron nitride) component) is reinforced with embedded fibers or rods 430 to enhance mechanical strength and reduce brittleness. For example, according to various embodiments, the interface component 402 may comprise one or more ceramics that are relatively brittle and may be reinforced using rods, fibers, etc.

[0052] In various embodiments, interface component 402 can be used in non-motor generator applications, such as for stationary electromagnetic components. In particular, for transformers with back iron members that maintain cooling, interface component 402 can be applied to cold plates and transformer laminations to improve thermal conductivity.

[0053] According to various embodiments, the motor includes a "slotless" or "semi-slotless" arrangement and cooling tubes located in the stator. The cooling tubes are electrically isolated from the conductive coils and magnetic lamination stack using a material with high thermal conductivity relative to conventional electrical insulating materials and acting as an electrical insulator (e.g., boron nitride, boron carbide, diamond, silicon carbide, etc.). In this embodiment, the interface components of the electrical insulating material are arranged around the cooling tubes made of conductive materials (e.g., stainless steel, steel, copper, copper-nickel alloys, etc.) and provide a greater thermal conduction path than conventional motor insulating materials (e.g., mica, polyimide, Nomex, etc.).

[0054] Figures 5A to 5B The illustrations show "slotless" arrangements without laminations and "semi-slotless" arrangements with partial lamination structures according to various embodiments of the present disclosure. As discussed more fully below, the various embodiments of the present disclosure do not include magnetically conductive materials, laminations, or lamination-type magnetic alloy structures. Other embodiments may include, as per [the following description]... Figure 5A and Figure 5B The “slotless” or “semi-slotless” electromagnetic arrangements discussed herein. Various embodiments of this disclosure can be applied to machines including stator slots. In other embodiments, the slots are removed and replaced with a non-magnetic material. According to various embodiments, enhanced cooling systems as described herein can be further applied to the electromagnetic topology.

[0055] Figure 5A Various embodiments of the present disclosure are shown, illustrating "slotless" arrangements without laminations. For example... Figure 5A As shown, the "slotless" electromagnetic arrangement does not include the stack of laminations 510. Therefore, at least some embodiments of this disclosure can be applied to slotless machines, such as holding machines and other slotless machines.

[0056] refer to Figure 5A Interface component 502 is formed around cooling pipe 504. In various embodiments, interface component 102 surrounding cooling pipe 504 can be used along the length of cooling pipe 504 (i.e., Figure 1BThe intermediate portion 150 shown dissipates heat. The material of the interface component 502 can be formed or deposited using various advanced manufacturing techniques, such as additive manufacturing, casting, hot pressing, sintering, or flame spraying, to eliminate gaps between loose components and enhance contact resistance between the main components. According to various embodiments, the interface component 502 may include electrically insulating and thermally conductive materials, such as boron nitride, boron carbide, diamond, silicon carbide, or any combination thereof. In an exemplary embodiment, the interface component 502 primarily comprises boron nitride. Figure 5A An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C).

[0057] According to various embodiments, the trenchless arrangement includes an interface component 502 deposited as a single integral piece between a first portion of the non-laminated low-permeability material 520 and a second portion of the non-laminated low-permeability material 521. Furthermore, the interface component 502 may be further deposited on top of the first electrical conductor 522. A second electrical conductor 524 may be disposed on top of the interface component 502. The first electrical conductor 522 may include the same material as the second electrical conductor 524, or the first electrical conductor 522 may include a different material than the second electrical conductor 524. In exemplary embodiments, and as shown... Figure 5A As shown, interface component 502 surrounds each side 526 of interface component 502.

[0058] like Figure 5A As shown, interface component 502 is configured such that interface component 502 encapsulates cooling pipe 504. The cooling pipe used throughout this disclosure may include stainless steel. Cooling pipe 504 may include conductive materials such as stainless steel, steel, copper, copper-nickel alloys, or any combination thereof. Figure 5A In the embodiment shown, cooling fluid flows into the drawing and passes through cooling pipe 504.

[0059] Figure 5B A "semi-slotless" arrangement with a partially laminated structure is shown according to various embodiments of the present disclosure. For example... Figure 5B As shown, the "semi-slotless" electromagnetic arrangement includes a stack of laminations 110, which at least partially contacts the interface component 502.

[0060] refer to Figure 5AInterface component 502 is formed around cooling pipe 504. In various embodiments, interface component 102 surrounding cooling pipe 504 can be used to dissipate heat along the length of cooling pipe 504. The material of interface component 502 can be formed or deposited using various advanced manufacturing techniques, such as additive manufacturing, casting, hot pressing, sintering, or flame spraying, to eliminate gaps between loose components and enhance contact resistance between the components to minimize their interaction. According to various embodiments, interface component 502 may include electrically insulating and thermally conductive materials, such as boron nitride, boron carbide, diamond, silicon carbide, or any combination thereof. In an exemplary embodiment, interface component 502 primarily comprises boron nitride. Figure 5B An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C).

[0061] According to various embodiments, the semi-grooveless arrangement includes an interface component 502 that can be deposited as a single integral piece between a first portion of the non-laminated low-permeability material 520 and a second portion of the non-laminated low-permeability material 521. In this embodiment, the stack 110 of the laminations can share a side surface 526 of the interface component 502. For example, the stack 110 of the laminations can form a portion of a contact side, and the first portion of the non-laminated low-permeability material 520 or the second portion of the non-laminated low-permeability material 521 can contact another portion of the same side.

[0062] Furthermore, the interface component 502 may be further deposited on top of the first electrical conductor 522. A second electrical conductor 524 may be disposed on top of the interface component 502. The first electrical conductor 522 may comprise the same material as the second electrical conductor 524, or the first electrical conductor 522 may comprise a different material than the second electrical conductor 524. In an exemplary embodiment, and as shown... Figure 5B As shown, interface component 502 surrounds each side 526 of interface component 502.

[0063] like Figure 5B As shown, interface component 502 is configured such that interface component 502 encapsulates cooling pipe 504. The cooling pipe used throughout this disclosure may include stainless steel. Cooling pipe 504 may include conductive materials such as stainless steel, steel, copper, copper-nickel alloys, or any combination thereof. Figure 5B In the embodiment shown, cooling fluid flows into the drawing and passes through cooling pipe 504.

[0064] Figure 6A A cross-sectional view is shown of an interface component 602 applied between a cold plate 604 and an electrical conductor according to various embodiments of the present disclosure. Figure 6A As shown, interface component 602 (such as...) Figure 5A The interface component 502 shown can be applied between the cold plate 604 and various other components to provide enhanced cooling. The cold plate 604 may define one or more fluid channels 605. In the illustrated embodiment, the interface component 602 is applied between the cold plate 604 and the conductive winding 606. The interface component 602 may include a crystalline or metallic material (e.g., boron nitride).

[0065] The interface component 602 can be applied directly to the cold plate 604 using advanced manufacturing techniques such as flame spraying or additive manufacturing, or a separate interface component 602 part can be applied at the interface point (e.g., between the cold plate 604 and the conductive winding 606).

[0066] Figure 6B A cross-sectional view of an interface component 622 applied between a cold plate 624 and a magnetic core 628, according to various embodiments of the present disclosure, is shown. Figure 6B As shown, interface component 622 (such as...) Figure 5A The interface component 502 shown can be applied between the cold plate 624 and various other components to provide enhanced cooling. The cold plate 624 may define one or more fluid channels 625. In the illustrated embodiment, the interface component 622 is applied between the cold plate 624 and the magnetic core 628.

[0067] In some embodiments, the interface component 622 includes a crystalline or metallic material (e.g., boron nitride) applied between the cold plate 624 and the magnetic core 628. The interface component 622 can be applied directly to the cold plate 624 using advanced manufacturing techniques such as flame spraying or additive manufacturing, or a separate interface component 622 part can be applied at an interface point (e.g., between the cold plate 604 and the magnetic core 628).

[0068] Figure 6C Cross-sectional views of interface components 632 applied between the cold plate 634 and the electrical conductor, and between the cold plate 634 and the magnetic core 638, according to various embodiments of the present disclosure are shown. Figure 6C As shown, interface component 622 is applied between cold plate 634 and electrical conductor, and between cold plate 634 and magnetic core 638. (Reference) Figure 6C Interface component 632 (such as Figure 5AThe interface component 502 shown can be applied between the cold plate 634 and various other components to provide enhanced cooling. The cold plate 634 may define one or more fluid channels 635. In the illustrated embodiment, the interface component 632 is applied between the cold plate 634 and the conductive winding 636, and between the cold plate 634 and the magnetic core 638. The interface component 632 may include a crystalline or metallic material (e.g., boron nitride) applied between the cold plate 634 and the conductive winding 636, and between the cold plate 634 and the magnetic core 638.

[0069] The interface component 632 can be applied directly to the cold plate 634 using advanced manufacturing techniques such as flame spraying or additive manufacturing, or a separate interface component 632 part can be applied at the interface point (e.g., between the cold plate 634 and the conductive winding 636 and / or between the cold plate 634 and the magnetic core 638).

[0070] Figure 7 Exemplary applications of the enhanced cooling embodiments described herein according to various embodiments of this disclosure are illustrated. According to various embodiments, interface component 702 may include an electrically insulating and thermally conductive material, such as boron nitride, boron carbide, diamond, silicon carbide, or any combination thereof. In exemplary embodiments, interface component 702 primarily includes boron nitride. Figure 7 An application of an advanced interface material incorporating boron nitride is illustrated. Boron nitride has good thermal conductivity, which helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures (e.g., less than or equal to 800°C).

[0071] System 700 may include an interface component 702 disposed between a cold plate 704 and a transformer core 706 having a transformer coil 708 disposed around the transformer core 706. In various embodiments, the cold plate 704 may be disposed between two interface components, as shown in the figure. As further shown, the interface component 702 may be disposed between the transformer coil 708 and the transformer core 706. Therefore, the interface component 702 can be applied at any interface between two components for electrical insulation and to increase the thermal conductivity of system 700.

[0072] In power-dense transformers, liquid-cooled cold plates can be embedded between laminated core sections and / or between electrical windings to improve thermal performance. In these cases, electrical insulators are typically located between the cold plate and the core and / or between the cold plate and the electrical windings to prevent short circuits from individual laminations or from the electrical windings to the grounded cold plate. Electrical insulators typically used at these interfaces are poor thermal conductors and negatively impact the thermal conductivity of the cooling circuit. Another application of the embodiments described herein may include replacing the electrical insulators used between the transformer core cold plates and the segmented laminated core sections and / or between the embedded cold plates and the transformer windings with advanced materials such as boron nitride. Boron nitride is electrically insulating while significantly increasing the thermal conductivity of the cooling system circuit.

[0073] According to at least one embodiment, the cooling tubes of the motor are located in stator slots, and the cooling tubes are electrically isolated from the conductive coils and magnetic lamination stack using a material with high thermal conductivity relative to conventional electrical insulating materials and acting as an electrical insulator (e.g., boron nitride, boron carbide, diamond, silicon carbide, etc.). In this embodiment, the interface components of the electrical insulating material are arranged around the cooling tubes made of conductive materials (e.g., stainless steel, steel, copper, copper-nickel alloys, etc.) and provide a greater thermal conduction path than conventional motor insulating materials (e.g., mica, polyimide, Nomex, etc.).

[0074] According to another embodiment, the electric motor (or generator) includes a stator comprising cooling tubes for removing waste heat, and the cooling tubes are electrically isolated from coil conductors and / or magnetic lamination stacks using a material that provides high thermal conductivity relative to conventional electrical insulating materials and acts as an electrical insulator. In this embodiment, interface components are arranged around the cooling tubes made of a conductive material (stainless steel, steel, copper, copper-nickel alloy, etc.).

[0075] According to another embodiment, the motor (or generator) includes a rotor, and the stator includes cooling tubes for removing waste heat. The cooling tubes are electrically isolated from the coil conductors and / or magnetic lamination stack using a material that provides high thermal conductivity relative to conventional electrical insulating materials and acts as an electrical insulator. In this embodiment, interface components are arranged around the cooling tubes made of a conductive material (e.g., stainless steel, steel, copper, copper-nickel alloy, etc.).

[0076] According to another embodiment, electrical components (e.g., transformers, inductors, or other filter components) including an electric winding further comprising a magnetic core with a cooling tube for removing waste heat are electrically isolated from the coil conductors and / or the magnetic core using one or more materials that provide high thermal conductivity relative to conventional electrical insulating materials and act as electrical insulators. In this embodiment, interface components are arranged around a cooling tube made of a conductive material (e.g., stainless steel, steel, copper, copper-nickel alloy, etc.).

[0077] Various embodiments of this disclosure can be used in applications such as marine or aerospace propulsion motors, marine or aerospace generators, marine or aerospace auxiliary motors, marine or aerospace power conversion inductors, marine or aerospace propulsion motor drive transformers, and filters. In some embodiments, the encapsulated cooling tubes described herein can be used in submarine applications.

[0078] Various examples of this disclosure are provided below. As used below, any reference to a series of examples should be understood as a reference to each of those examples separately (e.g., "Examples 1-4" should be understood as "Example 1, Example 2, Example 3, or Example 4").

[0079] Example 1 is a device including a cooling tube comprising a proximal end having a first opening and a distal end having a second opening. The cooling tube includes an intermediate portion extending between the proximal and distal ends. The device includes an interface component disposed on an external interface of the intermediate portion and at least partially enclosing the cooling tube, the interface component being made of an electrically insulating and thermally conductive material. The interface component is in abutment contact with one or more thermally conductive or heating elements of the electromechanical device.

[0080] Example 2 is the device of Example 1, wherein the interface components include a first part and a second part.

[0081] Example 3 is the device of Example 1-2, wherein the first part further includes a first interface, and the second part further includes a second interface, wherein the first interface and the second interface are in contact with a cooling pipe.

[0082] Example 4 is a device from Examples 1-3, where the first and second parts are mirror images of each other.

[0083] Example 5 is a device like Examples 1-4, where the width of the first part is less than or equal to the width of the second part.

[0084] Example 6 is a device of Examples 1-5, wherein the electrically insulating and thermally conductive material comprises boron nitride.

[0085] Example 7 is a device of Examples 1-6, wherein the electrically insulating and thermally conductive material comprises silicon carbide.

[0086] Example 8 is a device of Examples 1-7, wherein the electrically insulating and thermally conductive material includes heterogeneous composite materials, crystalline materials, or metallic materials.

[0087] Example 9 is a device of Examples 1-8, wherein the electrically insulating and thermally conductive material comprises boron carbide.

[0088] Example 10 is a device like those in Examples 1-9, wherein the electrically insulating and thermally conductive material comprises diamond.

[0089] Example 11 is the device of Examples 1-10, further comprising embedded fibers or rods disposed within an electrically insulating and thermally conductive material.

[0090] Example 12 is a system comprising a stator having a plurality of slots, a heat source adjacent to at least one of the plurality of slots, and a cooling pipe disposed in each of the plurality of slots. The cooling pipe is encapsulated by an electrically insulating and thermally conductive material disposed between the cooling pipe and each of the plurality of slots.

[0091] Example 13 is the system of Example 12, wherein the electrically insulating and thermally conductive material comprises boron nitride.

[0092] Example 14 is a system of Examples 12-13, wherein the electrically insulating and thermally conductive material comprises silicon carbide.

[0093] Example 15 is a system of Examples 12-14, wherein the electrically insulating and thermally conductive material comprises boron carbide.

[0094] Example 16 is a system of Examples 12-15, wherein the electrically insulating and thermally conductive material comprises diamond.

[0095] Example 17 is a system comprising a rotor having a plurality of slots, a heat source adjacent to at least one of the plurality of slots, and a cooling pipe disposed in each of the plurality of slots. The cooling pipe is encapsulated by an electrically insulating and thermally conductive material forming an interface between the cooling pipe and each of the plurality of slots.

[0096] Example 18 is a system of Example 17, wherein the electrically insulating and thermally conductive material comprises boron nitride.

[0097] Example 19 is a system of Examples 17-18, wherein the electrically insulating and thermally conductive material comprises silicon carbide.

[0098] Example 20 is a system of Examples 17-19, wherein the electrically insulating and thermally conductive material comprises boron carbide.

[0099] It should be noted that the methods, systems, and apparatus discussed above are intended only as examples. It must be emphasized that various processes or components may be appropriately omitted, substituted, or added in various embodiments. For example, it should be understood that in alternative embodiments, the method may be performed in a different order than described, and various steps may be added, omitted, or combined. Furthermore, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of embodiments can be combined in a similar manner. Moreover, it should be emphasized that technology is constantly evolving; therefore, many elements are illustrative and should not be construed as limiting the scope of the invention.

[0100] Specific details are set forth in the description to provide a thorough understanding of the embodiments. However, those skilled in the art will understand that the embodiments can be practiced without these specific details. For example, well-known processes, structures, and techniques have been shown without unnecessary detail to avoid obscuring the embodiments. This description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the foregoing description of the embodiments will provide those skilled in the art with an enabling description for implementing embodiments of the invention. Various changes can be made to the function and arrangement of elements without departing from the spirit and scope of the invention.

[0101] Several embodiments have been described, and those skilled in the art will recognize that various modifications, alternative constructions, and equivalents can be used without departing from the spirit of the invention. For example, the aforementioned elements may simply be components of a larger system, where other rules may take precedence over or otherwise modify the application of the invention. Furthermore, several steps may be taken before, during, or after considering the foregoing elements. Therefore, the foregoing description should not be considered as limiting the scope of the invention.

[0102] The technology described and claimed herein is not limited in scope to the specific preferred embodiments disclosed herein, as these embodiments are intended to illustrate various aspects of the technology and not to limit it. Any equivalent embodiments are intended to be within the scope of the technology. In fact, various modifications to the technology, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description. These modifications are also intended to fall within the scope of the appended claims.

Claims

1. An apparatus comprising: A cooling pipe includes a proximal end having a first opening and a distal end having a second opening, wherein the cooling pipe includes an intermediate portion extending between the proximal end and the distal end; and An interface component disposed on the outer interface of the intermediate portion and at least partially enclosing the cooling pipe, the interface component being made of an electrically insulating and thermally conductive material, wherein the interface component is in adjacent contact with one or more thermally conductive or heating elements of the electromechanical device.

2. The device according to claim 1, wherein, The interface component includes a first part and a second part.

3. The device according to claim 2, wherein, The first portion further includes a first interface, and the second portion further includes a second interface, wherein the first interface and the second interface are in contact with the cooling pipe.

4. The device according to claim 2, wherein, The first part and the second part are mirror images of each other.

5. The device according to claim 2, wherein, The width of the first part is less than or equal to the width of the second part.

6. The device according to claim 1, wherein, The electrically insulating and thermally conductive material includes boron nitride.

7. The device according to claim 1, wherein, The electrically insulating and thermally conductive material includes silicon carbide.

8. The device according to claim 1, wherein, The electrically insulating and thermally conductive material includes heterogeneous composite materials, crystals, or metallic materials.

9. The device according to claim 1, wherein, The electrically insulating and thermally conductive material includes boron carbide.

10. The device according to claim 1, wherein, The electrically insulating and thermally conductive material includes diamond.

11. The device of claim 1, further comprising embedded fibers or rods disposed within the electrically insulating and thermally conductive material.

12. A system comprising: The stator has multiple slots. A heat source, which is adjacent to at least one of the plurality of slots; as well as Cooling pipes are disposed in each of the plurality of slots. The cooling pipe is encapsulated by an electrically insulating and thermally conductive material, which is disposed between the cooling pipe and each of the plurality of slots.

13. The system according to claim 12, wherein, The electrically insulating and thermally conductive material includes boron nitride.

14. The system according to claim 12, wherein, The electrically insulating and thermally conductive material includes silicon carbide.

15. The system according to claim 12, wherein, The electrically insulating and thermally conductive material includes boron carbide.

16. The system according to claim 12, wherein, The electrically insulating and thermally conductive material includes diamond.

17. A system comprising: A rotor having multiple slots; A heat source, which is adjacent to at least one of the plurality of slots; as well as Cooling pipes are disposed in each of the plurality of slots. The cooling pipe is encapsulated by an electrically insulating and thermally conductive material, which forms an interface between the cooling pipe and each of the plurality of slots.

18. The system according to claim 17, wherein, The electrically insulating and thermally conductive material includes boron nitride.

19. The system according to claim 17, wherein, The electrically insulating and thermally conductive material includes silicon carbide.

20. The system according to claim 17, wherein, The electrically insulating and thermally conductive material includes boron carbide.

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