Electromagnetic Device Heat Transfer System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electromagnetic devices face challenges in effectively dissipating heat, particularly in smaller sizes, and are prone to increased operating temperatures, which affect electrical efficiency and bearing life, with existing cooling methods like air being inadequate and liquids posing risks of damage to motor components.
Innovation Solution
The use of a fluid-cooled electromagnetic device design featuring a heat transfer fluid sealed within a chamber made of injection molded thermoplastic material, which encapsulates conductors and inductors, and incorporates a heat transfer fluid confinement member and phase change material to facilitate efficient heat transfer and protection from corrosive environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air is used for cooling the motor, then the cooling system is simple, but the heat dissipation effectiveness is insufficient
Solution Approach 1:
The patent applies hydraulic cooling by circulating liquid coolant through channels in the stator core and rotor. The liquid cooling system efficiently removes heat generated during motor operation, solving the insufficient heat dissipation problem of air cooling while maintaining reasonable system complexity through integrated coolant channels in the motor structure.
2Temperature
If liquid coolant is used to improve heat dissipation, then heat dissipation effectiveness increases, but the risk of damaging motor components increases
Solution Approach 1:
The patent uses a waterproof coating or membrane on the stator windings and motor components to protect them from liquid coolant exposure. This allows the use of liquid cooling for improved heat dissipation while preventing coolant from damaging the electrical components, thus maintaining reliability.
Solution Approach 2:
The patent introduces a thermal interface material or heat transfer medium between the liquid coolant and the motor components. This intermediary layer enables efficient heat transfer from the motor to the coolant while preventing direct contact between the coolant and sensitive motor components, resolving the contradiction between heat dissipation effectiveness and component reliability.
3Volume of moving object
If the motor size is decreased, then the device becomes more compact, but the operating temperature increases
Solution Approach 1:
The patent implements liquid cooling channels directly within the compact motor structure, allowing efficient heat removal in a small volume. The integrated coolant pathways enable high heat flux density that can be achieved only with liquid cooling, thus maintaining low operating temperatures despite the reduced motor size.
Solution Approach 2:
The patent utilizes phase change materials or evaporative cooling mechanisms within the compact motor design. By leveraging phase transitions (such as evaporation or phase change material melting), the system achieves high heat dissipation capacity in a compact form factor, preventing temperature rise despite the small motor size.
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 design enhances heat dissipation, reduces operating temperatures, and protects components from corrosive environments, leading to improved motor efficiency and extended lifespan while allowing for the beneficial use of heat in directed applications.
Implementation Method 1
a heat transfer fluid substantially vaporizable at a temperature in the range of between about 25° C. and about 200° C., the heat transfer fluid being sealed in the chamber
Implementation Method 2
incorporates a heat transfer fluid confinement member and phase change material to facilitate efficient heat transfer
Data Source
AI summary
Electromagnetic components are provided with a heat exchange mechanism. For example, a fluid-cooled electromagnetic field-functioning device, such as a motor, generator, transformer, solenoid or relay, comprises one or more electrical conductors. A monolithic body of phase change material substantially encapsulates the conductors or an inductor. At least one liquid-tight coolant channel is also substantially encapsulated within the body of phase change material. The coolant channel may be part of a heat pipe or cold plate. The coolant channel may be made by molding a conduit into the body, using a “lost wax” molding process, or injecting gas into the molten phase change material while it is in the mold. The coolant channel may also be formed at the juncture between the body and a cover over the body.