Electromagnetic Device with Integrated Fluid Cooling
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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 insufficient and liquids posing risks of damage to motor components.
Innovation Solution
The use of a monolithic body of injection molded thermoplastic material encapsulating electrical conductors and inductors, with integrated fluid pathways and phase change materials to facilitate heat transfer and containment of heat transfer fluids, allowing for efficient heat dissipation and protection from corrosive environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (air) are used, then the device structure remains simple, but heat dissipation effectiveness is insufficient and operating temperature increases
Solution Approach 1:
The patent combines the housing structure with the cooling system by integrating fluid flow paths directly into the housing body. The housing serves dual functions as both structural enclosure and heat transfer conduit, eliminating the need for separate cooling components and reducing overall device complexity while improving heat dissipation effectiveness.
Solution Approach 2:
The patent introduces a heat transfer fluid as an intermediary substance to facilitate heat removal from the electromagnetic device. This fluid acts as a mediator between the heat-generating components and the external environment, enabling more effective heat dissipation compared to direct air cooling while maintaining a compact structure.
2Temperature
If liquid coolant is used to improve heat dissipation, then heat capacity increases, but risk of damage to motor components increases
Solution Approach 1:
The patent segments the device into distinct sealed regions: the electromagnetic component chamber and the fluid flow path chamber. This segmentation allows liquid coolant to be contained in dedicated pathways away from sensitive motor components, enabling effective heat dissipation while preventing liquid contact damage to electrical parts.
Solution Approach 2:
The patent uses sealed housings and barriers as intermediaries to separate the liquid coolant from the electromagnetic components. These protective barriers allow the liquid to perform its heat transfer function while preventing direct contact with motor components, thus maintaining both heat dissipation effectiveness and component reliability.
3Volume of moving object
If motor size is decreased, then device compactness improves, but operating temperature increases
Solution Approach 1:
The patent merges the cooling function directly into the motor housing structure, allowing compact motor design without sacrificing heat dissipation capability. The integrated fluid flow paths enable efficient heat removal from the compact motor components, maintaining lower operating temperatures despite reduced motor size.
Solution Approach 2:
The patent employs hydraulic cooling through liquid coolant flowing through integrated channels to remove heat from the compact motor. This hydraulic heat transfer system provides superior heat dissipation in a compact form factor compared to air cooling, enabling small motor size while maintaining acceptable operating temperatures.
4Ease of manufacture
If heat transfer fluid pathways are integrated into the housing, then manufacturing efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes injection molding technology to create fluid flow paths within the housing material. By changing the manufacturing parameter from mechanical machining to mold-based formation, the system achieves complex integrated pathways with consistent precision throughout production, improving manufacturing efficiency while maintaining required flow path accuracy.
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 management, reduced operating temperatures, enhanced motor efficiency, and protection of components from environmental damage, while allowing the heat transferred to be directed to a functional use, thus addressing the limitations of conventional cooling methods.
Implementation Method 1
heat transfer fluid flows through the device
Implementation Method 2
fluid in the environment of the device can be used to aid cooling
Implementation Method 3
phase change materials to facilitate 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, includes 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.