Enhanced cooling system for electromagnetic components

Abstract

Various embodiments of the present disclosure include apparatus and systems 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 and distal ends. The apparatus includes an interface member disposed on the outer interface of the intermediate portion and at least partially sealing the cooling tube, the interface member being made of an electrically insulating and thermally conductive material. The interface member is in contact with one or more heat-conducting or heat-generating elements of an electromechanical apparatus.

Description

[Technical Field]

[0001]

[0001] Cross-reference to related applications This application claims priority to U.S. Provisional Patent Application No. 63 / 586,923, filed on 29 September 2023, for the title of the invention, “Enhanced Cooling System for Electromagnetic Components,” the entire disclosure of which is incorporated herein by reference for all purposes. [Background technology]

[0002]

[0002] In various high-performance motors, cooling tubes may be used within the stator slots to cool the windings, coils, and other components. Cooling tubes are typically a more aggressive cooling mechanism than conventional air cooling techniques. [Overview of the Initiative] [Problems that the invention aims to solve]

[0003]

[0003] Despite the progress made in the field of high-performance motors, there is a need in the art for improved methods and systems for cooling the components of high-performance motors. [Means for solving the problem]

[0004]

[0004] This disclosure relates to electrically insulating and thermally conductive interface members, generally applied to cooling tubes in cooling systems. More specifically, embodiments of the present invention provide systems that use interface materials to enhance the thermal interface between conductive cooling system components, electrical windings, and electrical steel sheets or alloy cores. Embodiments of the present invention are applicable to a wide variety of power systems.

[0005]

[0005] Various embodiments of the present disclosure describe an interface member characterized by high thermal conductivity and low electrical conductivity. In various embodiments of the present disclosure, an interface member arrangement comprising an electrically insulating material surrounds the cylindrical cooling pipe and provides electrical insulation to the cooling pipe. In some embodiments, the interface member provides contact on all sides of the cooling pipe. In other embodiments, the cooling pipe is sealed within the interface member by other methods in a manner that renders it electrically insulating. The interface member may be a thermally conductive but non-conductive ceramic such as boron nitride, silicon carbide, or the like.

[0006]

[0006] The present disclosure achieves numerous advantages over the prior art. Embodiments of the present invention optimize cooling by electrically insulating the cooling pipes in the machine and increasing the thermal conductivity of the cooling pipes by providing the interface member in accordance with various techniques described herein. These and other embodiments of the present disclosure, along with many of its advantages and features, are described in greater detail in connection with the following text and the corresponding drawings. [Brief Description of the Drawings]

[0007] [Figure 1A] FIG. 2 is a cross-sectional view of a motor stator including an interface member, in accordance with one embodiment of the present disclosure. [Figure 1B] FIG. 3 is a perspective view of an interface member, in accordance with one embodiment of the present disclosure. [Figure 2] FIG. 4 is a cross-sectional view of a motor stator including an interface member dimensioned to fit within a slot using shims, in accordance with one embodiment of the present disclosure. [Figure 3] FIG. 5 is a cross-sectional view of a motor stator including an interface member dimensioned to fit within a slot, in accordance with one embodiment of the present disclosure. [Figure 4] FIG. 6 is a cross-sectional view of a motor stator including an interface member deposited in place within a slot, in accordance with one embodiment of the present disclosure. [Figure 5A]FIG. 1 illustrates a "slotless" configuration without lamination in accordance with various embodiments of the present disclosure. [Figure 5B] FIG. 3 illustrates a "semi-slotless" configuration having a partially laminated structure in accordance with various embodiments of the present disclosure. [Figure 6A] FIG. 5 illustrates a cross-sectional view of an interface member applied between a cold plate and an electrical conductor in accordance with various embodiments of the present disclosure. [Figure 6B] FIG. 7 illustrates a cross-sectional view of an interface member applied between a cold plate and a magnetically permeable core in accordance with various embodiments of the present disclosure. [Figure 6C] FIG. 9 illustrates a cross-sectional view of interface members applied between a cold plate and an electrical conductor, and between a cold plate and a magnetically permeable core in accordance with various embodiments of the present disclosure. [Figure 7] FIG. 11 illustrates an exemplary application of the enhanced cooling embodiments described herein in accordance with various embodiments of the present disclosure. DESCRIPTION OF EMBODIMENTS

[0008]

[0018] The present disclosure generally relates to electrically insulating and thermally conductive interface members applied to cooling tubes in cooling systems. More specifically, embodiments of the present invention provide a system that uses interface materials to enhance the thermal interface between conductive cooling system components, electrical windings, and electrical steel sheets or alloy cores. Embodiments of the present invention are applicable to a wide variety of power systems.

[0009]

[0019] The enhanced cooling systems for electromagnetic components described herein significantly improve the thermal performance (e.g., power density) of electromagnetic components, including but not limited to motors, generators, transformers, and inductors. Advanced materials such as boron nitride offer higher thermal conductivity than conventional electrical insulating materials and function as electrical insulators. Accordingly, various embodiments of this disclosure use boron nitride as an enhanced thermal interface between conductive cooling system components, electrical windings, and electrical steel sheets or alloy cores. The 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 circuit. Various embodiments described herein improve temperature by at least 30°C at operating current. Accordingly, regardless of the heat source, the interface members draw heat from the system for cooling.

[0010]

[0020] Conventional cooling tubes can be formed in a roughly square shape along their longitudinal direction. Inspecting cooling tubes formed in this way is time-consuming and expensive. The forming process is relatively complex and inaccurate. Cooling tubes that are not perfectly square do not have sufficient thermal contact on all sides, resulting in reduced thermal conductivity. Any electrical conduction through the cooling tube degrades its performance. In some conventional techniques, an electrically insulating slot liner is used between the cooling tube and the coil, which further reduces direct contact for cooling and creates a thermal barrier, negatively impacting cooling performance.

[0011]

[0021] The enhanced cooling systems for electromagnetic components described herein are in contrast to typical electromagnetic cooling methods, which include forced or natural convection air cooling, liquid cooling via an integrated back iron cold plate or cooling tubes, or direct cooling conductors (e.g., non-conductive fluids present inside or around coil conductors). This is also in contrast to less standard cooling configurations in which cooling tubes are preferentially located within the electromagnetic component, thereby positioning the tubes near a heat source (e.g., an electrical conductor) and insulated by an electrical insulating material exhibiting low thermal conductivity (e.g., plastics, aramid, polyimide, or woven products). The enhanced cooling systems have been fabricated with boron nitride interface member configurations and have demonstrated improved performance in several statorets showing improved thermal performance. Other embodiments of this disclosure may include other homogeneous or composite materials that function as electrical insulators while providing higher thermal conductivity than conventional electrical insulating materials. Various manufacturing techniques, such as machining, casting, 3D printing, and flame spray deposition, may be used.

[0012]

[0022] According to the various embodiments described herein, embodiments of the present invention can replace or complement existing conventional insulating materials such as "slot liners," "glass tape," and "mica tape" with unconventional materials (e.g., boron nitride, boron carbide, diamond, etc.) that exhibit high thermal conductivity and high electrical resistivity. For example, these materials having high thermal conductivity and high electrical resistivity minimize the insulation thickness and maximize the coil conductor cross-sectional area in order to minimize Joule loss in the machine, resulting in Joule loss ∝ 1 / copper cross-sectional area. In one exemplary embodiment, the material having high thermal conductivity and high electrical resistivity is 10 12 Boron nitride has an electrical volume resistivity exceeding ohms / cm, a dielectric breakdown strength of 10kV / mm to 230kV / mm, and a thermal conductivity of 10W / (mK) to 230W / (mK). In contrast, conventional insulating materials have a thermal conductivity in the range of 0.1W / mK to 1.0W / mK.

[0013]

[0023] Figure 1A shows a cross-sectional view of a motor stator 108 including an interface member 102 according to one embodiment of the present disclosure. According to various embodiments, the interface member 102 may include boron nitride, boron carbide, diamond, silicon carbide, or similar electrically insulating and thermally conductive materials, or any combination thereof. In an exemplary embodiment, the interface member 102 mainly comprises boron nitride. Figure 1A shows an example application of an advanced interface material comprising boron nitride. Boron nitride has suitable thermal conductivity to help dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C.

[0014]

[0024] According to various embodiments, the interface member 102 may contact one or more heat conduction or heat generation elements of the motor stator 108 or other electromechanical device. Such heat conduction or heat generation elements may include, for example, a heat source 114 or a lamination laminate 110. According to various embodiments, the interface member 102 may include multiple parts, or the interface member 102 may be a single, integrated piece. The interface member 102 may include a first part 103 and a second part 105, where the first part 103 and the second part 105 are mirror images of each other. In various embodiments, the interface member 102 includes multiple parts, such as at least three parts, at least four parts, etc. The first part 103 may include a first interface 107, and the second part 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. As shown in Figure 1A, the first interface 107 and the second interface 109 are curved so that they contact at least a portion of the cooling tube 104. For example, the first portion 103 has a width W P1 The second part 105 has a width W P2 The gap 111 between the first part 103 and the second part 105 is width W G It has. According to various embodiments, WP1 may be greater than, less than, or equal to W P2 . The slot 106 of the motor stator 108 including the first portion 103 and the second portion 105 may be characterized as having a width W S , where W S =W P1 +W P2 +W G . The gap 111 ensures that sufficient physical contact exists between the cooling tube 104 and the first portion 103 and second portion 105 of the interface member 102. The gap 111 ensures that the interface member 102 is sufficiently wedged against the slot 106 to provide sufficient thermal contact. In one exemplary embodiment, if the motor stator 108 is subsequently vacuum pressure impregnated (VPI), the gap 111 will be filled with resin during the VPI process performed on the completed motor stator assembly.

[0015]

[0025] In some embodiments, the first interface 107 and the second interface 109 contact the entire outer periphery of the cooling tube 104, and the slot 106 has a width W S , where 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 perimeter of the cooling tube 104. The cooling tube 104 may include a proximal end (e.g., facing toward the front of the page) having a first opening and a distal end (e.g., facing toward the back of the page) having a second opening. The cooling tube 104 may include an intermediate portion extending between the proximal end and the distal end.

[0016]

[0026] According to various embodiments and as shown in Figure 1A, 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 tube 104. The cooling tube used throughout this disclosure may include stainless steel. The cooling tube 104 may include a conductive material such as stainless steel, steel, copper, copper-nickel, or any combination thereof. In the embodiment shown in Figure 1A, the cooling fluid flows inward from the plane of the drawing and passes through the cooling tube 104.

[0017]

[0027] This embodiment shows a typical motor configuration. The motor stator 108 includes a lamination laminate 110 on each side of the slot 106. Current conducted through a heat source 114 (e.g., a coil) generates a magnetic flux within the lamination laminate 110 that interacts with the rotor (e.g., a rotating part of an electromachine), thereby generating torque in the rotor (not shown). To remove the heat generated within the motor stator 108, a cooling tube 104 may be included and electrically insulated from the lamination laminate 110 and the heat source 114. In various embodiments, the first portion 103 and the second portion 105 of the interface member 102 are positioned between an insulator 116 located on the heat source 114 and a top stick 118. The top stick 118 is a mechanical feature for holding various components within the slot 106 (e.g., the cooling tube 104, the first portion 103 and the second portion 105 of the interface member, etc.). According to some embodiments, the lamination laminate 110 contains grooves (not shown) into which the corresponding grooves (not shown) of the top stick 118 slide during assembly. The high electrical resistivity of boron nitride allows the cooling assembly to be placed in the slot 106 (e.g., stator slot) together with the heat source 114 without the need for additional electrical insulating material. Additional electrical insulating material can reduce the thermal conductivity of the entire cooling system. Boron nitride is available in different grades and is readily machinable. This allows for configurations with different slot widths and / or tube sizes. Any length or number of slots can be used. The cooling tube 104 can be made from any material compatible with the cooling medium.

[0018]

[0028] In various embodiments, the interface member 102 can be used in non-motorized generator applications such as for stationary electromagnetic components. In particular, for transformers having a back iron member that is kept in a cooled state, the interface member 102 can be applied to the cold plate and transformer lamination to improve thermal conductivity.

[0019]

[0029] Figure 1B shows a perspective view of an interface member according to one embodiment of the present disclosure. Figure 1B shows a motor stator 108 comprising a stator 130 having a plurality of slots. Each slot 106 may include an interface member 102 that seals a cooling tube 104. According to various embodiments, the interface member 102 may include boron nitride, boron carbide, diamond, silicon carbide, or similar electrically insulating and thermally conductive materials, or any combination thereof. In an exemplary embodiment, the interface member 102 mainly comprises boron nitride. Figure 1B shows an example application of an advanced interface material comprising boron nitride. Boron nitride has suitable thermal conductivity to help dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C.

[0020]

[0030] According to various embodiments, the interface member 102 may contact one or more heat conduction elements or heat generating elements of the motor stator 108 or other electromechanical device. Such heat conduction elements or heat generating elements may include, for example, a heat source 114 or a lamination laminate 110. According to various embodiments, the interface member 102 may consist of multiple parts, or the interface member 102 may be a single, integrated piece.

[0021]

[0031] The cooling tube 104 may include a proximal end 120 having a first opening 121 and a distal end 122 having a second opening 123. The cooling tube 104 may include an intermediate portion 150 (sealed by an interface member 102) extending between the proximal end 120 and the distal end 122. The cooling tubes used throughout this disclosure may include stainless steel. The cooling tube 104 may include conductive materials such as stainless steel, steel, copper, copper-nickel, or any combination thereof. In the embodiment shown in Figure 1B, the cooling fluid flows through the cooling tube 104 between the first opening 121 and the second opening 123.

[0022]

[0032] Figure 2 shows a cross-sectional view of a motor stator 208 including an interface member 202 sized to fit into a slot 206 using a shim 220, according to one embodiment of the present disclosure. According to various embodiments, the interface member 202 may include boron nitride, boron carbide, diamond, silicon carbide, or similar electrically insulating and thermally conductive materials, or any combination thereof. In exemplary embodiments, the interface member 202 mainly includes boron nitride. Figure 2 shows an example application of an advanced interface material including boron nitride. Boron nitride has suitable thermal conductivity to help dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C. The high electrical resistivity of boron nitride allows the cooling assembly to be placed in the slot 206 (e.g., stator slot) together with the heat source 214 without the addition of additional electrical insulating material. Additional electrical insulating material may reduce the thermal conductivity of the entire cooling system. Boron nitride is available in different grades and is readily machinable. This allows for the creation of shapes with different slot widths and / or tube sizes. Any length or number of slots can be used. The cooling tube 204 can be made from any material compatible with the cooling medium.

[0023]

[0033] According to various embodiments, the interface member 202 may include multiple parts, or the interface member 202 may be a single, integrated piece. The interface member 202 may include a first part 203 and a second part 205, where the first part 203 and the second part 205 are mirror images of each other. In various embodiments, the interface member 202 includes multiple parts, such as at least three parts and at least four parts. 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. As shown in Figure 2, the first interface 207 and the second interface 209 are curved such that they contact at least a portion of the cooling tube 204.

[0024]

[0034] According to some embodiments, the interface member 202 is made smaller in size to create a clearance fit within the slot 206. In various shapes as shown in Figure 2, a shim 220 may be used to tightly fit the interface member 202 that seals the cooling tube 204. The shim 220 may be used to wedge between the cooling assembly (e.g., the interface member 202 and the cooling tube 204) and the wall 217 of the slot 206, as shown in Figure 2. The shim 220 may include any combination of materials. In one exemplary embodiment, a G-11 glass epoxy laminate may be used for the shim 220 because it does not significantly degrade thermal performance.

[0025]

[0035] In this embodiment, the first portion 203 has a width W P1 The second part 205 has a width W P2 The gap 211 between the first part 203 and the second part 205 is width W GThe gap 211 ensures sufficient physical contact between the cooling tube 204 and the first portion 203 and the second portion 205 of the interface member 202. The gap 211 ensures that the interface member 202 is sufficiently wedged into the slot 206 to provide sufficient thermal contact. The slot 206 of the motor stator 208, including the first portion 203 and the second portion 205, has a width W S It can be characterized as having W P1 is W P2 Not equal to W S ≠W P1 +W P2 +W G Therefore, a shim 220 may be provided to fit the interface member 202 into the slot 206. The shim 220 has a width W that complements the width of the first portion 203 and the second portion 205. SH It may have W S =W P1 +W P2 +W G +W SH In various embodiments, one or more shims may be used, for example, a first shim adjacent to the first portion 203 and a second shim adjacent to the second portion 205 may be used.

[0026]

[0036] According to various embodiments and as shown in Figure 2, 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 tube 204. The cooling tube used throughout this disclosure may include stainless steel. The cooling tube 204 may include a conductive material such as stainless steel, steel, copper, copper-nickel, or any combination thereof. In the embodiment shown in Figure 2, the cooling fluid flows inward from the plane of the drawing and passes through the cooling tube 204.

[0027]

[0037] This embodiment shows a typical motor configuration. The motor stator 208 includes a lamination laminate 210 on each side of the slot 206. Current conducted through a heat source 214 (e.g., a coil) generates a magnetic flux within the lamination laminate 210 that interacts with the rotor, thereby generating torque in the rotor (not shown). To remove the heat generated within the motor stator 208, a cooling tube 204 may be included and is electrically isolated from the lamination laminate 210 and the heat source 214. In various embodiments, the first portion 203 and the second portion 205 of the interface member 202 are positioned between an insulator 216 located on the heat source 214 and a top stick 218. The top stick 218 is a mechanically featured portion for holding various components within the slot 206 (e.g., the cooling tube 204, the first portion 203 and the second portion 205 of the interface member, etc.). According to some embodiments, the lamination laminate 210 contains grooves (not shown) into which the corresponding grooves (not shown) of the top stick 218 slide during assembly. The high electrical resistivity of boron nitride allows the cooling assembly to be placed in the slots 206 (e.g., stator slots) together with the heat source 214 without the need for additional electrical insulating material. Additional electrical insulating material can reduce the thermal conductivity of the entire cooling system. Boron nitride is available in different grades and is readily machinable. This allows for configurations with different slot widths and / or tube sizes. Any length or number of slots can be used. The cooling tubes 204 can be made from any material compatible with the cooling medium.

[0028]

[0038] In various embodiments, the interface member 202 can be used in non-motorized generator applications such as for stationary electromagnetic components. In particular, for transformers having a back iron member that is kept in a cooled state, the interface member 202 can be applied to the cold plate and transformer lamination to improve thermal conductivity.

[0029]

[0039] Figure 3 shows a cross-sectional view of a motor stator 308, which includes an interface member 302 according to one embodiment of the present disclosure, which 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 is subsequently reduced in width, for example by polishing and lapping, to fit into the slot 306. According to various embodiments, the interface member 302 may include boron nitride, silicon carbide, boron carbide, diamond, or similar electrically insulating and thermally conductive materials, or any combination thereof. In exemplary embodiments, the interface member 302 mainly includes boron nitride. Figure 3 shows an example of an application of an advanced interface material including boron nitride. Boron nitride has suitable thermal conductivity to help dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C.

[0030]

[0040] According to various embodiments, the interface member 302 may include multiple parts, or the interface member 302 may be a single, integrated piece. The interface member 302 may include a first part 303 and a second part 305, where the first part 303 and the second part 305 are mirror images of each other. In various embodiments, the interface member 302 includes multiple parts, such as at least three parts and at least four parts. 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. As shown in Figure 3, the first interface 307 and the second interface 309 are curved so that the first interface 307 and the second interface 309 contact at least a portion of the cooling tube 304. For example, the first part 303 has a width W P1 The second part 305 has a width W P2 The gap 311 between the first part 303 and the second part 305 is width W GThe gap 311 ensures sufficient physical contact between the cooling tube 304 and the first portion 303 and the second portion 305 of the interface member 302. The gap 311 ensures that the interface member 302 is sufficiently wedged into the slot 306 to provide sufficient thermal contact.

[0031]

[0041] According to various embodiments, W P1 is W P2 It may be larger, smaller, or equal to. The slot 306 of the motor stator 308, including the first part 303 and the second part 305, has a width W S It can be characterized as having [a certain characteristic].

[0032]

[0042] In various embodiments, the assembly of the interface member 302 and the cooling pipe 304 has a width W of the slot 306. S It may be oversized to create an interference fit. During assembly, the interface member 302 may be polished or lapped to create a tight fit within the slot 306. For example, W P1 and / or W P2 is, W S =W P1 +W P2 +W G It can be reduced to the following extent.

[0033]

[0043] In some embodiments, the first interface 307 and the second interface 309 contact the entire outer circumference of the cooling tube 304, and the slot 306 has a width W S It has. Therefore, W P1 and / or W P2 is, W S =W P1 +W P2 It can be reduced to the following extent.

[0034]

[0044] According to various embodiments and as shown in Figure 3, 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 tube 304. The cooling tube used throughout this disclosure may include stainless steel. The cooling tube 304 may include a conductive material such as stainless steel, steel, copper, copper-nickel, or any combination thereof. In the embodiment shown in Figure 3, the cooling fluid flows inward from the plane of the drawing and passes through the cooling tube 304.

[0035]

[0045] This embodiment shows a typical motor configuration. The motor stator 308 includes a lamination laminate 310 on each side of the slot 306. Current conducted through a heat source 314 (e.g., a coil) generates a magnetic flux within the lamination laminate 310 that interacts with the rotor, thereby generating torque in the rotor (not shown). To remove the heat generated within the motor stator 308, a cooling tube 304 may be included and is electrically insulated from the lamination laminate 310 and the heat source 314. In various embodiments, the first portion 303 and the second portion 305 of the interface member 302 are positioned between an insulator 316 located on the heat source 314 and a top stick 318. The top stick 318 is a mechanically featured portion for holding various components within the slot 306 (e.g., the cooling tube 304, the first portion 303 and the second portion 305 of the interface member, etc.). According to some embodiments, the lamination laminate 310 contains grooves (not shown) into which the corresponding grooves (not shown) of the top stick 318 slide during assembly. The high electrical resistivity of boron nitride allows the cooling assembly to be placed in the slot 306 (e.g., stator slot) together with the heat source 314 without the need for additional electrical insulating material. Additional electrical insulating material can reduce the thermal conductivity of the entire cooling system. Boron nitride is available in different grades and is readily machinable. This allows for configurations with different slot widths and / or tube sizes. Any length or number of slots can be used. The cooling tube 304 can be made from any material compatible with the cooling medium.

[0036]

[0046] In various embodiments, the interface member 302 can be used in non-motorized generator applications such as for stationary electromagnetic components. In particular, for transformers having a back iron member that is kept in a cooled state, the interface member 302 can be applied to the cold plate and transformer lamination to improve thermal conductivity.

[0037]

[0047] Figure 4 shows a cross-sectional view of a motor stator 408 including an interface member 402 formed or deposited in situ according to one embodiment of the present disclosure. The material of the interface member 402 may be formed or deposited using additive manufacturing, casting, hot pressing, sintering, flame spraying, or various similar advanced manufacturing techniques to eliminate gaps between loosely fitted components and minimize contact resistance between objects. According to various embodiments, the interface member 402 may include boron nitride, boron carbide, diamond, silicon carbide, or similar electrically insulating and thermally conductive materials, or any combination thereof. In exemplary embodiments, the interface member 402 mainly comprises boron nitride. Figure 4 shows an example application of an advanced interface material containing boron nitride. Boron nitride has suitable thermal conductivity to help dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C.

[0038]

[0048] According to various embodiments, the interface member 402 may be deposited in the slot 406 as a single, integrated piece. As shown in Figure 4, the interface member 402 is positioned to seal the cooling tube 404 within the slot 406. The cooling tubes used throughout this disclosure may include stainless steel. The cooling tube 404 may include a conductive material such as stainless steel, steel, copper, copper-nickel, or any combination thereof. In the embodiment shown in Figure 4, the cooling fluid flows inward from the plane of the drawing and passes through the cooling tube 404. In at least some embodiments, the slot 406 of the motor stator 408 is the width W of the interface member 402. IS Width W equal to S It can be characterized as having [a certain characteristic].

[0039]

[0049] In this embodiment, a typical motor arrangement is shown. The motor stator 408 includes a lamination laminate 410 on each side of the slot 406. Current conducted through a heat source 414 (e.g., a coil) generates a magnetic flux within the lamination laminate 410 that interacts with the rotor, thereby generating torque in the rotor (not shown). To remove the heat generated within the motor stator 408, a cooling tube 404 may be included and is electrically insulated from the lamination laminate 410 and the heat source 414. In various embodiments, an interface member 402 is positioned between an insulator 416 located on the heat source 414 and a top stick 418. The top stick 418 is a mechanically featured part for holding various components within the slot 406 (e.g., the cooling tube 404 and the interface member 402). According to some embodiments, there are grooves (not shown) within the lamination laminate 410 into which the corresponding grooves (not shown) of the top stick 418 slide during assembly. The high electrical resistivity of boron nitride allows the cooling assembly to be placed in the slot 406 (e.g., stator slot) together with the heat source 414 without the need for additional electrical insulating material. Additional electrical insulating material can reduce the overall thermal conductivity of the cooling system. Boron nitride is available in different grades and is readily machinable. This allows for configurations with different slot widths and / or tube sizes. Any length or number of slots can be used. The cooling tube 404 can be made from any material compatible with the cooling medium.

[0040]

[0050] In various embodiments, the interface member 402 (e.g., a heterogeneous, composite crystalline, or metallic (e.g., boron nitride) member) is reinforced with embedded fibers or rods 430 to improve mechanical strength and reduce brittleness. For example, according to various embodiments, the interface member 402 may comprise one or more relatively brittle ceramics, which may be reinforced with rods, fibers, or similar materials.

[0041]

[0051] In various embodiments, the interface member 402 can be used in non-motorized generator applications such as for stationary electromagnetic components. In particular, for transformers having a back iron member that is kept in a cooled state, the interface member 402 can be applied to the cold plate and transformer lamination to improve thermal conductivity.

[0042]

[0052] According to various embodiments, the electromachine includes a "slotless" or "semi-slotless" configuration and cooling tubes arranged within a stator. The cooling tubes are electrically insulated from the conductive coils and magnetic permeable lamination laminates using a material (e.g., boron nitride, boron carbide, diamond, silicon carbide, or similar) that has a higher thermal conductivity than conventional electrical insulating materials and functions as an electrical insulator. In this embodiment, the interface member configuration of the electrical insulating material surrounds the cooling tubes made of a conductive material (e.g., stainless steel, steel, copper, copper-nickel, or similar) and provides a larger heat conduction path than conventional electromechanical insulating materials (e.g., mica, polyimide, Nomex, or similar).

[0043]

[0053] Figures 5A and 5B show both “slotless” configurations without lamination and “semi-slotless” configurations having partially laminated structures, according to various embodiments of the present disclosure. As will be discussed more thoroughly below, various embodiments of the present disclosure do not involve permeable materials, laminations, or laminated magnetic alloy structures. Other embodiments may include “slotless” or “semi-slotless” electromagnetic configurations, as discussed in relation to Figures 5A and 5B. Various embodiments of the present disclosure may be applied to machines including stator slots. In other embodiments, the slots are removed and replaced with non-magnetic materials. According to various embodiments, the enhanced cooling systems described herein may be applied to electromagnetic topologies.

[0044]

[0054] Figure 5A shows a “slotless” configuration without lamination according to various embodiments of the present disclosure. As shown in Figure 5A, the “slotless” electromagnetic configuration does not include a lamination laminate 510. Therefore, at least some embodiments of the present disclosure may be applied to non-slot machines such as holdback machines and other slotless machines.

[0045]

[0055] Referring to Figure 5A, the interface member 502 is formed around the cooling tube 504. In various embodiments, the interface member 502 surrounding the cooling tube 504 may be used to dissipate heat along the length of the cooling tube 504 (i.e., along the intermediate portion 150 shown in Figure 1B). The material of the interface member 502 may be formed or deposited using additive manufacturing, casting, hot pressing, sintering, or flame spraying, or various similar advanced manufacturing techniques, to eliminate gaps between loosely fitted components and minimize contact resistance between objects. According to various embodiments, the interface member 502 may include boron nitride, boron carbide, diamond, silicon carbide, or similar electrically insulating and thermally conductive materials, or any combination thereof. In exemplary embodiments, the interface member 502 mainly comprises boron nitride. Figure 5A shows an example application of an advanced interface material containing boron nitride. Boron nitride has suitable thermal conductivity to help dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C.

[0046]

[0056] According to various embodiments, the slotless configuration includes the interface member 502 being deposited as a single, integrated piece between a first portion of a non-laminated low-permeability material 520 and a second portion of a non-laminated low-permeability material 521. Furthermore, the interface member 502 may also be deposited on top of a first electrical conductor 522. A second electrical conductor 524 may be placed on top of the interface member 502. The first electrical conductor 522 may contain the same material as the second electrical conductor 524, or the first electrical conductor 522 may contain a different material than the second electrical conductor 524. In an exemplary embodiment, as shown in Figure 5A, the interface member 502 is surrounded on each side 526 of the interface member 502.

[0047]

[0057] As shown in Figure 5A, the interface member 502 is positioned to seal the cooling tube 504. The cooling tubes used throughout this disclosure may include stainless steel. The cooling tube 504 may include a conductive material such as stainless steel, steel, copper, copper-nickel, or any combination thereof. In the embodiment shown in Figure 5A, the cooling fluid flows inward from the plane of the drawing and passes through the cooling tube 504.

[0048]

[0058] Figure 5B shows a “semi-slotless” configuration having a partially laminated structure according to various embodiments of the present disclosure. As shown in Figure 5B, the “semi-slotless” electromagnetic configuration includes a lamination laminate 510 that is at least partially in contact with the interface member 502.

[0049]

[0059] Referring to Figure 5B, the interface member 502 is formed around the cooling tube 504. In various embodiments, the interface member 502 surrounding the cooling tube 504 may be used to dissipate heat along the length of the cooling tube 504. The material of the interface member 502 may be formed or deposited using additive manufacturing, casting, hot pressing, sintering, or flame spraying, or various similar advanced manufacturing techniques, to eliminate gaps between loosely fitted components and minimize contact resistance between objects. According to various embodiments, the interface member 502 may include boron nitride, boron carbide, diamond, silicon carbide, or similar electrically insulating and thermally conductive materials, or any combination thereof. In exemplary embodiments, the interface member 502 mainly comprises boron nitride. Figure 5B shows an example application of an advanced interface material containing boron nitride. Boron nitride has a suitable thermal conductivity that helps to dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C.

[0050]

[0060] According to various embodiments, the semi-slotless configuration includes the fact that the interface member 502 may be deposited as a single, integrated piece between a first portion of the unlaminated low-permeability material 520 and a second portion of the unlaminated low-permeability material 521. In this embodiment, the lamination laminate 110 may share a side portion 526 of the interface member 502. For example, the lamination laminate 510 may form contact with a portion of its side portion, and the first portion of the unlaminated low-permeability material 520 or the second portion of the unlaminated low-permeability material 521 may be in contact with other portions of the same side portion.

[0051]

[0061] Furthermore, the interface member 502 may be further deposited on top of the first electrical conductor 522. The second electrical conductor 524 may be placed on top of the interface member 502. The first electrical conductor 522 may contain the same material as the second electrical conductor 524, or the first electrical conductor 522 may contain a different material than the second electrical conductor 524. In an exemplary embodiment, as shown in Figure 5B, the interface member 502 is surrounded on each side 526 of the interface member 502.

[0052]

[0062] As shown in Figure 5B, the interface member 502 is positioned to seal the cooling tube 504. The cooling tubes used throughout this disclosure may include stainless steel. The cooling tube 504 may include a conductive material such as stainless steel, steel, copper, copper-nickel, or any combination thereof. In the embodiment shown in Figure 5B, the cooling fluid flows inward from the plane of the drawing and passes through the cooling tube 504.

[0053]

[0063] Figure 6A shows a cross-sectional view of an interface member 602 applied between a cold plate 604 and an electrical conductor according to various embodiments of the present disclosure. As shown in Figure 6A, the interface member 602 (such as the interface member 502 shown in Figure 5A) may be applied between the cold plate 604 and various other components to provide an enhanced cooling effect. The cold plate 604 may define one or more fluid passages 605. In the illustrated embodiment, the interface member 602 is applied between the cold plate 604 and a conductive winding 606. The interface member 602 may include a crystalline or metallic material (e.g., boron nitride).

[0054]

[0064] The interface member 602 may be directly applied to the cold plate 604 using advanced manufacturing technologies such as flame spraying or additive manufacturing, or individual pieces of the interface member 602 may be applied to interface points (for example, between the cold plate 604 and the conductive winding 606).

[0055]

[0065] Figure 6B shows a cross-sectional view of an interface member 622 applied between a cold plate 624 and a magnetic core 628 according to various embodiments of the present disclosure. As shown in Figure 6B, the interface member 622 (such as the interface member 502 shown in Figure 5A) may be applied between the cold plate 624 and various other components to provide an enhanced cooling effect. The cold plate 624 may define one or more fluid passages 625. In the illustrated embodiment, the interface member 622 is applied between the cold plate 624 and the magnetic core 628.

[0056]

[0066] In some embodiments, the interface member 622 includes a crystalline or metallic material (e.g., boron nitride) applied between the cold plate 624 and the magnetic core 628. The interface member 622 may be applied directly to the cold plate 624 using advanced manufacturing techniques such as flame spraying or additive manufacturing, or individual pieces of the interface member 622 may be applied to interface points (e.g., between the cold plate 604 and the magnetic core 628).

[0057]

[0067] Figure 6C shows a cross-sectional view of an interface member 632 applied between a cold plate 634 and an electrical conductor, and between a cold plate 634 and a magnetic core 638, according to various embodiments of the present disclosure. As shown in Figure 6C, the interface member 622 is applied both between the cold plate 634 and the electrical conductor, and between the cold plate 634 and the magnetic core 638. Referring to Figure 6C, the interface member 632 (such as the interface member 502 shown in Figure 5A) may be applied between the cold plate 634 and various other components to provide an enhanced cooling effect. The cold plate 634 may define one or more fluid passages 635. In the illustrated embodiment, the interface member 632 is applied between the cold plate 634 and a conductive winding 636, and between the cold plate 634 and the magnetic core 638. The interface member 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 magnetically permeable core 638.

[0058]

[0068] The interface member 632 may be directly applied to the cold plate 634 using advanced manufacturing techniques such as flame spraying or additive manufacturing, or individual pieces of the interface member 632 may be applied to interface points (for example, between the cold plate 634 and the conductive winding 636 and / or between the cold plate 634 and the magnetically permeable core 638).

[0059]

[0069] Figure 7 shows exemplary applications of the enhanced cooling embodiments described herein, according to various embodiments of the present disclosure. According to various embodiments, the interface member 702 may include boron nitride, boron carbide, diamond, silicon carbide, or similar electrically insulating and thermally conductive materials, or any combination thereof. In exemplary embodiments, the interface member 702 mainly includes boron nitride. Figure 7 shows an example application of an advanced interface material including boron nitride. Boron nitride has suitable thermal conductivity to help dissipate heat from the motor stator. Boron nitride can be used at high temperatures, for example, below 800°C.

[0060]

[0070] The system 700 may include an interface member 702 positioned between a cold plate 704 and a transformer core 706 having transformer coils 708 arranged around the transformer core 706. In various embodiments, as shown in the figure, the cold plate 704 may be positioned between the two interface members. As further shown, the interface member 702 may be positioned between the transformer coils 708 and the transformer core 706. Thus, the interface member 702 may be applied to any interface between two components to electrically insulate the system 700 and increase its thermal conductivity.

[0061]

[0071] In high-power-density transformers, liquid-cooled cold plates may be embedded between laminated core sections and / or between sets of electrical windings to improve thermal performance. In these cases, electrical insulators are typically placed between the cold plate and the core and / or between the cold plate and the electrical windings to prevent short circuits in each lamination or between the electrical windings and the grounded cold plate. The electrical insulators typically used at these interfaces are poor thermal conductors and negatively affect the thermal conductivity of the cooling circuit. Another application of the embodiments described herein may involve replacing the electrical insulators used between the transformer core cold plate and the divided laminated core sections and / or between the embedded cold plates and the transformer windings with an advanced material such as boron nitride. Boron nitride materials provide electrical insulation while significantly increasing the thermal conductivity of the cooling system circuit.

[0062]

[0072] According to at least one embodiment, the cooling tubes of an electromechanical device are arranged in stator slots and electrically insulated from conductive coils and magnetic permeable lamination laminates using a material (e.g., boron nitride, boron carbide, diamond, silicon carbide, or similar) that has a higher thermal conductivity than conventional electrical insulating materials and functions as an electrical insulator. In this embodiment, the interface member configuration of the electrical insulating material surrounds the cooling tubes made of a conductive material (e.g., stainless steel, steel, copper, copper-nickel, or similar) and provides larger heat conduction paths than conventional electromechanical insulating materials (e.g., mica, polyimide, Nomex, or similar).

[0063]

[0073] In another embodiment, the electromachine (motor or generator) includes a stator with cooling tubes for waste heat removal, and the cooling tubes are electrically insulated from the coil conductors and / or magnetically permeable lamination laminate using a material that provides higher thermal conductivity than conventional electrical insulating materials and functions as an electrical insulator. In this embodiment, an interface member configuration is used to surround the cooling tubes made of a conductive material (stainless steel, steel, copper, copper-nickel, or similar).

[0064]

[0074] In another embodiment, the electromachine (motor or generator) includes a rotor with cooling tubes for removal or waste heat, and the cooling tubes are electrically insulated from the coil conductors and / or magnetically permeable lamination laminate using a material that provides higher thermal conductivity than conventional electrical insulating materials and functions as an electrical insulator. In this embodiment, an interface member configuration is used to surround the cooling tubes made of a conductive material (e.g., stainless steel, steel, copper, copper-nickel, or similar).

[0065]

[0075] In other embodiments, an electrical component (e.g., a transformer, inductor, or other filter component) including an electric winding and a permeable core, and further including a cooling tube for waste heat removal, and the cooling tube, are electrically insulated from the coil conductor and / or permeable core using a material that provides higher thermal conductivity than conventional electrical insulating materials and functions as an electrical insulator. In this embodiment, an interface member configuration is used to surround the cooling tube made of a conductive material (e.g., stainless steel, steel, copper, copper-nickel, or similar).

[0066]

[0076] Various embodiments of this disclosure may be used in 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, or similar applications. In some embodiments, the sealing cooling tubes described herein may be used in submarine applications.

[0067]

[0077] Examples of the various aspects of this disclosure are shown below. When used herein, any reference to the set of examples should be understood as a selective reference to each of those examples (for example, “Examples 1-4” should be understood as “Examples 1, 2, 3, or 4”).

[0068]

[0078] Example 1 is a device including a cooling tube having a proximal end with a first opening and a distal end with a second opening. The cooling tube includes an intermediate portion extending between the proximal and distal ends. The device includes an interface member disposed on the outer interface of the intermediate portion and at least partially sealing the cooling tube, the interface member being made of an electrically insulating and thermally conductive material. The interface member is in contact with one or more heat-conducting or heat-generating elements of an electromechanical device.

[0069]

[0079] Example 2 is the same apparatus as in Example 1, and the interface member includes a first part and a second part.

[0070]

[0080] Example 3 is the apparatus of Examples 1 and 2, wherein the first part further includes a first interface, the second part further includes a second interface, and the first and second interfaces are in contact with a cooling tube.

[0071]

[0081] Example 4 is the apparatus of Examples 1-3, where the first and second parts are mirror images of each other.

[0072]

[0082] Example 5 is the same apparatus as in Examples 1-4, where the width of the first part is less than or equal to the width of the second part.

[0073]

[0083] Example 6 is the apparatus of Examples 1-5, and the electrically insulating and thermally conductive material contains boron nitride.

[0074]

[0084] Example 7 is the apparatus of Examples 1-6, and the electrically insulating and thermally conductive material contains silicon carbide.

[0075]

[0085] Example 8 is the apparatus of Examples 1-7, and the electrically insulating and thermally conductive material includes heterogeneous composite materials, crystalline materials, or metallic materials.

[0076]

[0086] Example 9 is the apparatus of Examples 1-8, and the electrically insulating and thermally conductive material contains boron carbide.

[0077]

[0087] Example 10 is the apparatus of Examples 1-9, and the electrically insulating and thermally conductive material includes diamond.

[0078]

[0088] Example 11 is the apparatus of Examples 1 to 10, further including embedded fibers or rods placed within an electrically insulating and thermally conductive material.

[0079]

[0089] Example 12 is a system including a stator having a plurality of slots, a heat source in contact with at least one of the plurality of slots, and a cooling tube disposed within each of the plurality of slots. The cooling tube is sealed by an electrically insulating and thermally conductive material placed between the cooling tube and each slot.

[0080]

[0090] Example 13 is the system of Example 12, in which the electrically insulating and thermally conductive material includes boron nitride.

[0081]

[0091] Example 14 is a system of Examples 12-13, in which the electrically insulating and thermally conductive material contains silicon carbide.

[0082]

[0092] Example 15 is a system of Examples 12-14, in which the electrically insulating and thermally conductive material contains boron carbide.

[0083]

[0093] Example 16 is a system of Examples 12-15, in which the electrically insulating and thermally conductive material includes diamond.

[0084]

[0094] Example 17 is a system comprising a rotor having multiple slots, a heat source in contact with at least one of the multiple slots, and a cooling tube positioned within each of the multiple slots. The cooling tube is sealed with an electrically insulating and thermally conductive material that forms an interface between the cooling tube and each slot.

[0085]

[0095] Example 18 is the system of Example 17, in which the electrically insulating and thermally conductive material includes boron nitride.

[0086]

[0096] Example 19 is a system of Examples 17-18, in which the electrically insulating and thermally conductive material contains silicon carbide.

[0087]

[0097] Example 20 is a system of Examples 17-19, in which the electrically insulating and thermally conductive material contains boron carbide.

[0088]

[0098] It should be noted that the methods, systems, and apparatus described above are intended to be merely examples. It should be emphasized that various embodiments may, as appropriate, omit, substitute, or add various procedures or components. For example, it should be understood that in alternative embodiments, the methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Also, features described in relation to one embodiment may be combined in various other embodiments. Different aspects and elements of embodiments may be combined in similar ways. Furthermore, it should be emphasized that technology is evolving, and therefore many elements are examples and should not be interpreted as limiting the scope of the invention.

[0089]

[0099] Specific details are given in the description to provide a full understanding of the embodiments. However, those skilled in the art will understand that the embodiments can be carried out without these specific details. For example, well-known processes, structures, and techniques are shown without unnecessary detail to avoid obscuring the embodiments. This description provides only exemplary embodiments and is not intended to limit the scope, applicability, or configuration of the invention. Rather, prior descriptions of embodiments will provide those skilled in the art with a practical guide for carrying out embodiments of the invention. Various modifications can be made to the function and arrangement of the elements without departing from the spirit and scope of the invention.

[0090]

[0100] Having described several embodiments, those skilled in the art will recognize that various modifications, alternative configurations, and equivalents can be used without departing from the spirit of the invention. For example, the elements described above may be merely components of a larger system, in which case other rules may take precedence over or otherwise modify the application of the invention. Furthermore, several steps may be performed before, during, or after the elements are considered. Therefore, the above description should not be taken as limiting the scope of the invention.

[0091]

[0101] The art described and claimed herein should not be limited in scope by any particular preferred embodiments disclosed herein, for these embodiments are illustrative, not limiting, of some aspects of the art. Any equivalent embodiment is intended to fall within the scope of this art. Indeed, in addition to those shown and described herein, various modifications of this art will become apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.

Claims

1. It is a device, A cooling tube having a proximal end with a first opening and a distal end with a second opening, and including an intermediate portion extending between the proximal end and the distal end, An interface member disposed on the outer interface of the intermediate portion and sealing the cooling tube at least partially, made of an electrically insulating and thermally conductive material, wherein the interface member is in contact with one or more thermally conductive or heat-generating elements of an electromechanical device, and A device equipped with the following features.

2. The apparatus according to claim 1, wherein the interface member includes a first portion and a second portion.

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

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

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

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

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

8. The apparatus according to claim 1, wherein the electrically insulating and thermally conductive material includes a heterogeneous composite material, a crystalline material, or a metallic material.

9. The apparatus according to claim 1, wherein the electrically insulating and thermally conductive material contains boron carbide.

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

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

12. It is a system, A stator having multiple slots, A heat source in contact with at least one of the plurality of slots, Cooling tubes arranged in each of the aforementioned multiple slots Equipped with, A system in which the cooling tubes are sealed by an electrically insulating and thermally conductive material placed between the cooling tubes and each of the slots.

13. The system according to claim 12, wherein the electrically insulating and thermally conductive material comprises 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. It is a system, A rotor having multiple slots, A heat source in contact with at least one of the plurality of slots, Cooling tubes arranged in each of the aforementioned multiple slots Equipped with, A system in which the cooling tubes are sealed with an electrically insulating and thermally conductive material that forms an interface between the cooling tubes and each of the slots.

18. The system according to claim 17, wherein the electrically insulating and thermally conductive material comprises 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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