Electromagnetic Device Heat Transfer Flow Path
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Solution Overview
Problem
Conventional electromagnetic devices face challenges in effectively dissipating heat, particularly in smaller sizes, and often require complex cooling methods that are inefficient or prone to damage from corrosive environments, leading to reduced performance and lifespan.
Innovation Solution
The integration of a heat transfer fluid pathway within a monolithic body of injection molded thermoplastic material that encapsulates electrical conductors and inductors, utilizing phase change materials and heat pipes to facilitate efficient heat transfer and protection from corrosive environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (fans, air cooling) are used, then the device structure remains simple, but heat dissipation effectiveness is insufficient and operating temperature increases
Solution Approach 1:
The patent applies hydraulic cooling by circulating liquid coolant through channels formed in the injection molded body. The fluid pathway allows efficient heat transfer from the electromagnetic components to the coolant, significantly improving heat dissipation effectiveness compared to air cooling methods.
Solution Approach 2:
The patent uses a composite structure combining injection molded thermoplastic material with embedded heat transfer fluid pathways. This composite approach integrates cooling functionality directly into the structural body, enabling effective heat removal while maintaining design flexibility and component integration.
2Loss of energy
If liquid coolant is introduced for cooling, then heat dissipation improves, but the risk of motor damage from fluid contact increases
Solution Approach 1:
The patent merges the cooling system with the motor housing by forming the fluid pathways directly in the injection molded body. This integration ensures that the coolant is contained within dedicated channels, preventing contact with electrical components while maintaining efficient heat transfer. The structural body itself becomes the cooling system boundary.
Solution Approach 2:
The injection molded body acts as a flexible yet rigid containment structure for the coolant. The molded material forms sealed pathways that约束 the fluid, providing both structural integrity and fluid containment to prevent leakage and component damage.
3Loss of energy
If multiple separate components are used for cooling, then cooling effectiveness improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple functions into a single integrated component. The injection molded body simultaneously provides structural support, houses electromagnetic components, and contains the cooling fluid pathways. This integration eliminates the need for separate cooling system components, reducing overall device complexity while maintaining effective cooling.
Solution Approach 2:
The injection molded body serves multiple functions: it provides the structural housing for the motor, contains and positions electromagnetic components, forms the cooling fluid pathways, and acts as a thermal management system. This multi-functionality reduces the number of separate components needed while achieving effective heat dissipation.
4Productivity
If precise tolerances are maintained for component assembly, then motor performance improves, but manufacturing difficulty and cost increase
Solution Approach 1:
By integrating the cooling pathways directly into the motor housing through injection molding, the patent eliminates the need for separate assembly of cooling components. The fluid pathways are formed as integral features of the housing, ensuring precise alignment and tolerances without requiring complex assembly procedures or additional machining operations.
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 enables improved heat dissipation, reduced operating temperatures, and enhanced protection of components from corrosive environments, leading to increased efficiency and extended lifespan of electromagnetic devices.
Implementation Method 1
a heat transfer fluid pathway is defined by at least one channel in the monolithic body covered by the mating component, with at least one fluid inlet and at least one fluid outlet to the pathway to allow for passage of heat transfer fluid through the pathway
Implementation Method 2
utilizing phase change materials and heat pipes to facilitate efficient heat transfer
Implementation Method 3
utilizing phase change materials and heat pipes to facilitate efficient heat transfer
Implementation Method 4
utilizing phase change materials and heat pipes 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.