Coil Wire Insulation Softening for Thermal Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Coils for electrical machines, particularly in high-performance electric motors and generators, face challenges with heat dissipation due to the thermal contact resistance between the coil wire and the insulator, leading to inefficient heat transfer and potential overheating.
Innovation Solution
The method involves enlarging the contact surface area between the coil wire and the insulating body by softening and pressing the solid coating and insulating body, allowing for better micro-surface adaptation and direct heat transfer, eliminating the need for additional encapsulation materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coil wire is wound with precision windings guided by guides on the pole shoe or insulating body, then the winding precision is improved, but the heat dissipation capability deteriorates due to reduced contact area between coil wire and insulator
Solution Approach 1:
The patent changes the physical state of the coating material from solid to softened state through thermal or chemical treatment, enabling the coating to flow and adapt to the insulator surface, thereby increasing the contact area between coil wire and insulator for improved heat dissipation while maintaining winding precision
Solution Approach 2:
The patent utilizes phase transition of the coating material (from solid to softened/melted state and back to solid) to achieve better contact between coil wire and insulator. The coating is softened or melted to fill gaps and then solidifies to maintain the enhanced contact area, resolving the contradiction between precision and heat dissipation
2Temperature
If additional encapsulation materials are used to improve heat dissipation, then the heat transfer efficiency is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the heat dissipation function from separate encapsulation materials and integrates it directly into the coil wire coating itself. The coating material serves dual purposes: electrical insulation and heat dissipation, eliminating the need for additional encapsulation layers and simplifying the overall structure
Solution Approach 2:
The patent makes the coating material multi-functional by enabling it to perform both its traditional insulation function and an additional heat dissipation function. Through softening and pressing, the coating directly contacts the insulator to conduct heat away from the coil wire, eliminating the need for separate heat dissipation 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 approach significantly reduces thermal contact resistance, ensuring effective heat dissipation and maintaining adhesion over a wide temperature range, enhancing the coil's performance and longevity by allowing for higher electrical power handling and compact design.
Implementation Method 1
the solid insulating body (2) is softened thermally or chemically for a predeterminable period of time at least in the area of the first contact surface (41)
Implementation Method 2
the solid insulating body (2) is softened thermally or chemically for a predeterminable period of time
Implementation Method 3
and the coating (31) of the coil wire (3) and the insulating body (2) are at least intermittently pressed together during this predeterminable period of time
Implementation Method 4
the thermal contact resistance between the coil wire and the insulator, ie the thermal resistance during heat flow from the warmer coil wire into the cooler insulator, is significantly reduced
Data Source
Figure 1~4
Figure 5~9
Figure 10~13
AI summary
In a method for manufacturing a coil (1) for an electrical machine, in particular an electric motor, wherein a solid insulating body (2), in particular in a winding machine, is arranged, and subsequently at least one coil wire (3) having a solid insulating coating (31) is wound to form a winding over the insulating body (2), wherein the coil wire (3) is contacted in certain areas with the insulating body (2), wherein the sum of the area orFor the purpose of creating a first contact surface between the coil wire (3) and the insulating body (2) after winding, in order to enlarge the first contact surface into a second contact surface in a form-fitting manner, it is proposed that the solid coating (31) of the coil wire (3) and/or the solid insulating body (2) is subsequently softened thermally or chemically for a predetermined period of time, at least in the area of the first contact surface, and that the coating (31) of the coil wire (3) and the insulating body (2) are pressed together at least temporarily during this predetermined period of time.