Coil Module With Annular Cooling Channel For Electric Machine
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Solution Overview
Problem
Existing electrical machine designs face inefficiencies due to flat wire electromagnetic characteristics and difficulties in achieving high density and multi-phase structures, along with inadequate cooling solutions.
Innovation Solution
A coil module with a coil disk featuring a coil carrier made of insulating material and multiple conductive windings arranged around a center point, where active regions contribute to torque and are thicker axially, while passive regions are thinner and overlap to maximize copper filling, allowing for a compact, efficient design and effective cooling through a built-in cooling channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If flat wire is used to achieve high density of electrically conductive material, then copper filling is improved, but electromagnetic efficiency deteriorates
Solution Approach 1:
The patent applies local quality by using round wire instead of flat wire specifically in the active regions where electromagnetic efficiency is critical, while maintaining high copper filling through optimized winding geometry and packing arrangement. This local adaptation resolves the contradiction by matching material shape to functional requirements.
2Adaptability or versatility
If multi-phase structure is implemented, then functionality is improved, but structural complexity increases
Solution Approach 1:
The patent segments the winding structure into modular coil disks with standardized winding patterns that can be independently configured for different phase arrangements. This segmentation allows multi-phase functionality to be achieved through modular assembly rather than complex integrated structures, reducing overall structural complexity.
3Temperature
If cooling channels are added, then thermal management is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling channel function with the existing coil disk structure by integrating coolant flow paths through the coil carrier and winding assembly. This combination eliminates the need for separate cooling components, achieving effective thermal management without proportionally increasing device complexity.
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 enhances power density and efficiency by optimizing winding placement and cooling, enabling a more powerful and space-saving electrical machine.
Implementation Method 1
each of the windings (13) having two active regions (16) running radially from the center (14) and two passive regions (17a, 17b) running tangentially at its radially outer and inner edge
Implementation Method 2
the active areas (16) of different windings (13) do not overlap one another, but each passive area (17a, 17b) of one of the windings (13) partially overlaps the corresponding passive areas (17a, 17b) of the two immediately adjacent windings (13)
Implementation Method 3
The first coil disk (6) and the second coil disk (6) are attached to one another in such a way that between the first coil disk (6) and the second coil disk (6) through the substantially annular recess (22) a substantially annular cooling channel (23) is formed for a coolant
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a coil module (18) for an electric machine comprising: a first coil disk (6) with at least one winding (13) made of an electrically conductive material; a second coil disk (6) with at least one winding (13) made of an electrically conductive material; wherein the first coil disk (6) and/or the second coil disk (6) have a substantially annular recess (22); wherein the first coil disk (6) and the second coil disk (6) are arranged such that a substantially annular cooling channel (23) for a coolant is formed between the first coil disk (6) and the second coil disk (6) by the substantially annular recess (22).