Ceramic Coil Former for Electrical Machine Heat Dissipation

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Solution Overview

Problem

The thermal load-bearing capacity of stator-end coil assemblies in electrical machines limits the permissible power throughput, and existing solutions do not effectively dissipate heat to enhance machine power in a constant installation space.

Innovation Solution

A coil assembly using a ceramic material for the coil former combined with a metal coil produced by molding, which provides high thermal conductivity for efficient heat dissipation and electrical insulation, allowing the coil former to function as both a holder and a mold, eliminating the need for de-molding and enhancing the slot filling factor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a plastic coil former is used to hold the coil, then the coil assembly can be easily manufactured, but the thermal conductivity is insufficient to dissipate heat effectively

Engineering Contradiction:

Improveease of manufactureVSAvoidheat dissipation

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent changes the material parameter of the coil former from plastic to ceramic material, which fundamentally alters the thermal conductivity property. This parameter change enables effective heat dissipation while maintaining the structural function of the coil former, directly resolving the contradiction between ease of manufacture and heat dissipation capability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs ceramic material for the coil former, which can be considered a composite material solution that combines high thermal conductivity with electrical insulation properties. This material selection allows the coil former to simultaneously serve as a structural holder and a heat dissipation component, resolving the contradiction between manufacturing ease and thermal performance.

Inventive Principle:

Principle #40Composite materials

2Temperature

If a ceramic material is used for the coil former, then heat dissipation is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveheat dissipationVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The ceramic coil former is designed to perform multiple functions simultaneously: it serves as the structural holder for the coil, provides thermal conduction for heat dissipation, and offers electrical insulation. This multi-functionality reduces the need for additional separate components, thereby managing device complexity while achieving superior heat dissipation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the functions of the coil holder and the heat dissipation component into a single ceramic coil former structure. By combining these functions into one integrated component rather than using separate parts, the design achieves effective heat dissipation without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If the coil is wound around the coil former, then the coil can be easily formed, but the slot filling factor is reduced

Engineering Contradiction:

Improveease of formationVSAvoidslot filling factor

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Instead of the conventional approach of winding the coil around the coil former, the patent inverts the process by molding the coil directly onto or into the coil former. This inversion of the manufacturing sequence allows for more efficient space utilization and increases the slot filling factor while maintaining ease of manufacture through the molding process.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the manufacturing method parameter from winding to molding. This parameter change in the formation process enables the coil to be directly shaped onto the coil former, achieving both ease of manufacture through automated molding and improved slot filling factor by eliminating the gaps inherent in wound coil structures.

Inventive Principle:

Principle #35Parameter changes

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

This configuration increases the power yield and efficiency of the electrical machine by optimizing heat dissipation and electrical insulation, enabling higher power throughput without increasing installation space.

Implementation Method 1

Heat is transferred from the coil of the respective coil assembly to the stator-end support of the electrical machine. Ceramic materials have a high level of thermal conductivity, and therefore heat can be dissipated effectively from the coil of the coil assembly.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

A coil former composed of a ceramic material also has very good electrical insulation properties so that electrical flashovers can be prevented.

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS9991037B2Electrical machine, coil assembly for an electrical machine, and method for producing said coil assembly

Publication Date: 2018.06.05 DR ING H C F PORSCHE AG

AI summary

A coil assembly (11) for an electrical machine has a coil former (12) composed of an electrically non-conductive material and a coil (13) held by the coil former (12) is composed of an electrically conductive material. The coil former (12) is produced from a ceramic material, the coil (13) is in the form of a coil molding.