Ceramic Insulated Conductors With Cooling Channels for Heat Dissipation
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Solution Overview
Problem
Conventional insulated conductors in electric machines suffer from cracks, wrinkles, and voids that lead to partial discharge and inadequate heat dissipation, resulting in potential electrical or structural failures due to low thermal conductivity of commonly used insulators like mica tape.
Innovation Solution
The use of ceramic insulators with recesses and high thermal conductivity materials such as alumina and zirconia, along with conductors that define cooling channels, to enhance thermal management and reduce partial discharge, combined with joining techniques that minimize voids and maximize contact surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional insulators like mica tape are used, then insulation is provided, but thermal conductivity is low (0.2 to 0.3 W/mK) preventing effective heat dissipation
Solution Approach 1:
The patent changes the material parameter of the insulator from conventional mica tape (0.2-0.3 W/mK thermal conductivity) to ceramic materials with high thermal conductivity. This parameter change enables effective heat dissipation while maintaining electrical insulation properties, resolving the contradiction between heat dissipation capability and insulation reliability.
Solution Approach 2:
The patent employs composite material structures including ceramic insulators combined with cooling channels and thermal management systems. This composite approach integrates both electrical insulation and active cooling functions, simultaneously achieving reliable insulation and effective heat dissipation.
2Reliability
If conventional wrapping techniques are used to form windings, then conductors are insulated, but cracks, wrinkles, or voids are created that lead to partial discharge
Solution Approach 1:
The patent extracts and eliminates the problematic voids and air pockets from the insulation structure by implementing solid ceramic insulator blocks with integrated cooling channels. This removes the source of partial discharge while maintaining ease of manufacture through standardized component assembly.
Solution Approach 2:
The patent uses solid, non-porous ceramic materials to eliminate the voids and air pockets that cause partial discharge in conventional wrapped insulations. The dense ceramic structure provides continuous electrical insulation without the discontinuities that lead to discharge paths.
3Temperature
If high thermal conductivity materials are used, then heat dissipation is improved, but manufacturing complexity increases due to joining techniques required
Solution Approach 1:
The patent merges the insulator and cooling channel functions into a single integrated ceramic component. This consolidation eliminates the need for complex joining techniques between separate insulator and cooling system parts, reducing manufacturing complexity while maintaining high thermal conductivity through the integrated structure.
Solution Approach 2:
The ceramic insulator serves multiple functions simultaneously: electrical insulation, thermal conduction, and structural support for cooling channels. This multi-functionality reduces the number of separate components and joining operations required, simplifying the overall manufacturing process despite using advanced 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
This solution significantly increases thermal conductivity by 100 times and allows for higher operating temperatures, reducing the risk of electrical failure and improving heat dissipation in electric machine windings.
Implementation Method 1
The thermal conductivity of commonly used mica tape insulators is around 0.2 to 0.3 W/mK, which is lower than desired, preventing the windings from dissipating heat at a desirable rate
Implementation Method 2
conductors that define cooling channels
Implementation Method 3
cooling channels that may be in fluid communication with one another
Data Source
AI summary
An article can include a ceramic insulator with an interior surface defining a recess, an insulator aperture in the interior surface, and an insulator cooling channel extending through at least a portion of the ceramic insulator to the insulator aperture. A first conductor can be at least partially disposed within the recess.