Bare Conductor Cooling with Dielectric Fluid
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Solution Overview
Problem
Conventional cooling methods for electric machines are ineffective due to the electrical insulator acting as a barrier for heat transfer between conductors and coolant, leading to reduced cooling effectiveness.
Innovation Solution
Direct cooling of bare conductors using an electrically insulating fluid that is in physical contact with the outer surfaces of the conductors, providing both cooling and electrical insulation, with the fluid being characterized by high dielectric strength, specific heat capacity, and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical insulator is used to isolate conductors, then electrical insulation is improved, but heat transfer between conductors and coolant deteriorates
Solution Approach 1:
The patent removes the electrical insulator from between the conductor and coolant, allowing direct thermal contact. The insulator is extracted from the thermal path while electrical insulation is maintained through alternative means (fluid selection or geometric spacing), resolving the contradiction by eliminating the thermal barrier.
Solution Approach 2:
The patent changes the properties of the cooling fluid from conductive (water) to electrically insulating (dielectric fluid), thereby simultaneously achieving both thermal contact and electrical insulation. This parameter change in the fluid's electrical properties resolves the contradiction without compromising either function.
2Reliability
If conventional cooling methods are used with electrical insulators, then electrical insulation is maintained, but cooling effectiveness deteriorates
Solution Approach 1:
The patent introduces an electrically insulating dielectric fluid as an intermediary between the conductor and the cooling system. This mediator enables direct thermal contact while maintaining electrical insulation, thereby improving cooling effectiveness without sacrificing electrical insulation reliability.
Solution Approach 2:
The patent employs a composite approach by selecting a cooling fluid that combines both cooling and insulation properties (dielectric fluid). This composite material serves dual functions, resolving the contradiction between maintaining electrical insulation and achieving effective cooling.
3Temperature
If liquid coolant is used for cooling, then cooling effectiveness is improved, but electrical insulation between conductors deteriorates
Solution Approach 1:
The patent changes the electrical parameter of the cooling fluid from conductive to insulating by selecting dielectric fluids with high breakdown voltage. This parameter change enables the fluid to provide both effective cooling and electrical insulation simultaneously.
Solution Approach 2:
The patent extracts the electrical conductivity property from the cooling fluid, removing the harmful electrical conduction while retaining the beneficial thermal conduction. This selective extraction allows the fluid to cool effectively without compromising electrical insulation.
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
Enhances cooling effectiveness by direct contact with conductors, overcoming the limitations of conventional methods and improving heat transfer while providing electrical insulation.
Implementation Method 1
provides direct fluid cooling for the plurality of bare conductors
Implementation Method 2
the fluid is electrically insulating and provides direct fluid cooling for the plurality of bare conductors and electrical insulation between consecutive bare conductors
Data Source
AI summary
An electric machine comprising a rotor, a stator, a plurality of bare conductors forming a plurality of windings in at least one of the stator and the rotor, and a fluid in direct physical contact with a plurality of outer surfaces of the plurality of bare conductors, wherein the fluid is electrically insulating and provides direct fluid cooling, to provide cooling for the plurality of bare conductors and electrical insulation between consecutive bare conductors of the plurality of bare conductors.