Automotive Electrical Machine Heat Dissipation via Insertable Module

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Solution Overview

Problem

Existing electrical machines in the automotive sector with heat transmission devices are difficult and costly to produce, as their housings require complex assembly processes.

Innovation Solution

An electrical machine design featuring a housing with a clearance for a prefabricated heat transmission module that can be easily inserted and adapted, allowing for efficient heat dissipation, using materials like aluminum or composite materials, and incorporating a heat sink with cooling end pieces for effective heat exchange.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the housing is designed with integrated heat transmission device as in prior art (DE 10 2011 038 529 A1), then heat dissipation is achieved, but manufacturing complexity and assembly effort increase significantly

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidassembly effort

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heat transmission device is separated from the housing and provided as an independent prefabricated module that can be inserted into the housing through a clearance. This segmentation allows the housing and heat transmission device to be manufactured separately and assembled easily, reducing assembly effort while maintaining heat dissipation functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat transmission device is extracted from the housing structure and provided as a separate insertable module. This extraction enables independent optimization of the housing design for ease of manufacture while the heat transmission module can be independently designed and manufactured with optimal heat dissipation features.

Inventive Principle:

Principle #2Taking out (Extraction)

2Temperature

If the heat transmission device is custom-designed for each application, then heat dissipation is optimized, but manufacturing cost and complexity increase

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoiddesign adaptation complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The prefabricated heat transmission module is designed as a universal component that can be adapted to different electrical machine configurations by selecting appropriate modules with different power ratings. The standardized module design with universal mounting features reduces design complexity while maintaining optimized heat dissipation for various applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Different heat transmission modules are available with varying parameters such as power output ratings, clearance dimensions, and thermal conductivity characteristics. By selecting modules with appropriate parameters for each application, optimized heat dissipation is achieved without requiring custom design work, thus reducing device complexity.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If the housing material has high thermal conductivity, then heat removal is improved, but manufacturing flexibility and cost increase

Engineering Contradiction:

Improveheat removal efficiencyVSAvoidmanufacturing flexibility

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The housing can be made from composite materials such as plastic composites (CRP) or metal-ceramic composites (MMC) that provide reduced thermal conductivity while maintaining structural integrity. The separate heat transmission module inserted into the housing provides the necessary thermal pathways, allowing the housing material to be selected based on manufacturing ease and cost rather than thermal performance alone.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates easy and cost-effective production of electrical machines with improved heat dissipation capabilities, enabling efficient heat removal and adaptation to varying power outputs and forms, while allowing for integration with air-conditioning systems.

Implementation Method 1

a heat transmission device provided in the housing... heat produced can be removed reliably

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

fluid-cooled electrical machine that has a housing with a cooling device to cool the electrical machine

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

The heat transmission module may have a heat sink and two formed-on cooling end pieces

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 4

The heat transmission module may have a heat sink and two formed-on cooling end pieces

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS9461525B2Electrical machine for use in the automotive sector

Publication Date: 2016.10.04 DR ING H C F PORSCHE AG

AI summary

An electrical machine for an automotive vehicle has a housing (4). A stator arrangement (8) and a rotor arrangement (6) are disposed in the housing (4). At least one clearance (10) is formed in the housing (4) in proximity to the stator arrangement (8) and the rotor arrangement (6). A heat transmission device (12) is inserted into the clearance (10) as a prefabricated heat transmission module.