Electromagnetic Device Heat Transfer with Phase Change Material
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Solution Overview
Problem
Conventional electromagnetic devices face challenges in effectively dissipating heat, particularly in smaller sizes, leading to increased operating temperatures that affect electrical efficiency and bearing life, and they struggle with incorporating liquid coolants without damaging the motor components.
Innovation Solution
The development of fluid-cooled electromagnetic devices featuring a monolithic body of injection molded thermoplastic material that encapsulates electrical conductors and inductors, with a non-linear heat transfer fluid pathway and phase change material, allowing for efficient heat transfer and protection from corrosive environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional cooling methods (air fans) are used, then the device structure is simple, but the heat dissipation efficiency is insufficient due to low heat capacity of air
Solution Approach 1:
The patent transitions from air cooling (gas) to liquid coolant cooling (hydraulics). The liquid coolant system with pumps, channels, and heat exchangers provides superior heat capacity and heat transfer efficiency compared to air fans, directly resolving the heat dissipation insufficiency while accepting increased system complexity.
Solution Approach 2:
The patent utilizes phase change material (PCM) that transitions between solid and liquid states to absorb and store thermal energy. This phase transition mechanism enables passive heat dissipation and temperature regulation, significantly improving heat dissipation efficiency without requiring continuous active cooling.
2Loss of energy
If liquid coolant is introduced for cooling, then heat dissipation efficiency improves, but the risk of damaging motor components increases
Solution Approach 1:
The patent introduces thermal interface materials and thermal barriers as intermediaries between the liquid coolant and motor components. These intermediaries transfer heat efficiently from the components to the coolant while protecting the components from direct contact with the liquid, thus maintaining reliability while achieving effective cooling.
Solution Approach 2:
The patent employs thin film coatings and flexible barriers that conform to component surfaces, providing protective layers that prevent liquid coolant from damaging sensitive motor components while maintaining thermal contact for efficient heat transfer.
3Volume of moving object
If smaller motor size is used, then device compactness improves, but operating temperature increases
Solution Approach 1:
The patent integrates cooling channels and phase change material directly within the motor structure, nesting the cooling system inside the motor housing and components. This allows efficient heat dissipation in a compact form factor, enabling smaller motor size without excessive temperature increase.
Solution Approach 2:
The phase change material absorbs excess heat through phase transition (solid to liquid), actively managing temperature in the compact motor. This enables the motor to maintain lower operating temperatures despite the reduced size and increased heat density.
4Loss of energy
If heat sinks are incorporated, then heat dissipation improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the heat sink function with the motor housing and internal structures. The housing itself is designed with integrated cooling channels and thermal pathways, eliminating the need for separate heat sink components and reducing manufacturing complexity while maintaining effective heat dissipation.
Solution Approach 2:
The motor housing serves multiple functions: structural support, electromagnetic shielding, and heat dissipation through integrated cooling channels. This multi-functionality eliminates the need for separate dedicated heat dissipation components, simplifying manufacturing while improving heat transfer efficiency.
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 flows through the device
Implementation Method 2
a water pump driven by a motor uses the water to cool the pump
Implementation Method 3
with a non-linear heat transfer fluid pathway and phase change material
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.