Gas-Gap Magnetic Sheet Stack for Higher Thermal Load Capacity
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Solution Overview
Problem
Existing magnetic sheet stacks in electric machines have limited thermal load capacity due to the use of insulating materials, which restricts their practical application.
Innovation Solution
The implementation of a magnetic sheet stack with a non-vanishing clearance between magnetic sheets, utilizing ceramic spacers to maintain electrical insulation and allow for defined air gaps, enabling effective cooling and increased thermal load capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thin electrically insulating polymer layers are introduced between magnetic sheets, then electrical insulation is improved, but thermal load capacity deteriorates
Solution Approach 1:
The invention changes the physical state of the insulating medium from solid polymer layer to gas-filled clearance. This parameter change (from solid to gas phase) allows the insulating structure to withstand higher temperatures since gases can operate at elevated temperatures without degrading, thus resolving the contradiction between maintaining electrical insulation and improving thermal load capacity
Solution Approach 2:
The invention introduces gas (air or other gases) as the insulating medium between magnetic sheets by creating clearances. This pneumatic approach replaces solid polymer insulation with gas-filled spaces, enabling better thermal performance while maintaining electrical insulation properties through the gas dielectric barrier
2Temperature
If magnetic sheets are spaced apart with clearances, then thermal load capacity is improved, but mechanical stability deteriorates
Solution Approach 1:
The invention introduces spacers as intermediary elements between magnetic sheets. These spacers serve dual functions: they maintain the necessary clearances for thermal management while providing mechanical support to ensure stack stability. The spacers act as mediators that reconcile the conflicting requirements of thermal performance and mechanical stability
Solution Approach 2:
The invention uses composite structures combining magnetic sheets with spacer materials. This composite approach integrates different materials with complementary properties - the magnetic sheets provide electromagnetic functionality while the spacers provide mechanical stability and thermal clearance, together forming a structurally sound assembly that meets both thermal and mechanical requirements
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 configuration enhances the temperature load capacity of the magnetic sheet stack, allows for efficient cooling through defined gaps, and provides high mechanical stability, thereby expanding design freedoms for electric machines.
Implementation Method 1
the magnetic sheets (20) of the magnetic sheet stack are electrically insulated from one another over the predominant part of their planar extents in each case by an intermediately disposed gas layer
Implementation Method 2
the magnetic sheet stack can be cooled with a cooling fluid
Data Source
AI summary
Various embodiments of the teachings herein include a magnetic sheet stack for an electric machine comprising: a plurality of magnetic sheets electrically insulated from one another by being spaced apart from one another predominantly with a non-vanishing clearance; a respective set of ceramic spacers distributed between each of the plurality of magnetic sheets from an adjacent sheet in the stack; and a respective gas layer filling a gap between a predominant part of a planar extent of each of the plurality of magnetic sheets allowing a cooling fluid to be circulated between the adjacent sheets.