Fluid-Cooled Stator Assemblies Using Thermally Conductive Polymer Conduits
Solution Overview
Problem
Electrical machines with electromagnetic systems face inefficiencies due to thermal energy buildup from electrical and mechanical losses, which traditional air cooling methods inadequately address, leading to reduced lifespan and reliability, especially under varying loads.
Innovation Solution
The implementation of fluid-cooled stator assemblies using thermally conductive polymer conduits that circulate a thermal management fluid in a heat exchange relation with the stator core and windings, providing enhanced heat transfer coefficients while preventing direct contact and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air cooling is used to dissipate thermal energy, then the system is simple and convenient, but the heat transfer coefficient is low requiring high air flow rates and large pressure differentials
Solution Approach 1:
The patent transitions from air cooling to liquid cooling by circulating thermal management fluid through conduits in direct contact with the stator core. This hydraulic approach achieves significantly higher heat transfer coefficients compared to pneumatic air cooling, allowing effective thermal management without requiring high air flow rates and large pressure differentials that would demand complex air handling equipment
2Temperature
If liquid coolant is used for cooling, then the heat transfer coefficient is significantly higher, but the system becomes complicated and requires direct contact between coolant and heat-generating portions
Solution Approach 1:
The patent uses thermally conductive polymer conduits as intermediaries between the liquid coolant and the stator core. These conduits are in direct thermal contact with the heat-generating portions, allowing efficient heat transfer from the stator to the coolant while the conduit structure simplifies the overall system design and eliminates the need for complex cooling arrangements
3Temperature
If direct contact between liquid coolant and electromagnetic system is used, then cooling efficiency is high, but the coolant may short, corrode, and degrade system performance
Solution Approach 1:
The thermally conductive polymer conduits serve as protective intermediaries that are in direct thermal contact with the stator core while containing the liquid coolant. This arrangement allows high cooling efficiency through direct thermal contact while preventing the coolant from causing short circuits, corrosion, or degradation of the electromagnetic system components
4Temperature
If high air flow rates are used to compensate for low heat transfer coefficients, then cooling effectiveness is maintained, but large and loud air handling equipment is required
Solution Approach 1:
The patent adopts liquid cooling through thermally conductive polymer conduits, which provides significantly higher heat transfer coefficients than air cooling. This eliminates the need for high air flow rates and the associated large, loud air handling equipment, achieving effective cooling with a more compact and quieter system
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 effectively manages thermal energy dissipation, improving the efficiency and lifespan of electrical machines by utilizing thermally conductive polymers to enhance heat transfer without compromising electrical insulation or machine integrity.
Implementation Method 1
at least a portion of the thermal management conduit has a wall formed of a thermally conductive polymer
Implementation Method 2
the thermal management conduit is configured to convey the thermal management fluid in a heat exchange relation with at least the stator core
Data Source
AI summary
A fluid-cooled stator assembly for electrical machines. The stator assembly may include a stator core having a back iron portion and a plurality of stator teeth. Each of the plurality of stator teeth may be separated from each other by at least one of plurality of slots, the slots being structured to receive placement of stator windings. The apparatus also includes a thermal management conduit that is positioned at various locations about the stator assembly, including within or along the back iron portion, stator teeth, slots, and/or among the stator windings. Further, the thermal management conduit may provide insulation for one or more coils of the stator windings. Additionally, at least a portion of the thermal management conduit may be formed from a thermally conductive polymer. The thermal management conduit is configured to convey a thermal management fluid in a heat exchange relationship with the stator assembly.