Insulated Wire Cooling Channel Structure for Direct Heat Dissipation
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Solution Overview
Problem
Existing electromagnetic wire cooling methods in drive motors suffer from low heat conduction efficiency due to a small contact area between the cooling tube and the wire, leading to slow and inefficient cooling.
Innovation Solution
An insulated wire design with a sunken part and convex part in the insulating layer allows for a direct contact cooling channel, enhancing heat conduction efficiency and cooling speed by increasing the contact area between the cooling medium and the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling tube is introduced between electromagnetic wires to improve cooling efficiency, then the cooling medium can flow through the tube, but the contact area between the cooling tube and the electromagnetic wire is small, resulting in low heat conduction efficiency
Solution Approach 1:
The insulating layer acts as an intermediary between the electromagnetic wire and the cooling channel, allowing direct thermal contact while maintaining electrical insulation. The sunken part in the insulating layer creates a cooling channel that is in direct contact with the wire surface, solving the contradiction by providing both thermal conduction path and electrical insulation.
Solution Approach 2:
The cooling channel is formed by creating a sunken part in the insulating layer rather than using a separate cooling tube. This dimensional change from a tubular structure to a planar sunken channel increases the contact area with the wire surface while maintaining the cooling function.
2Temperature
If the depth of the sunken part (L2) is increased to improve cooling effect, then better heat dissipation is achieved, but the insulating layer thickness increases which impedes heat dissipation and reduces the number of coil layers that can be wound
Solution Approach 1:
The patent optimizes the parameters L1 and L2 of the sunken part to achieve the best cooling effect. By controlling the depth L2 within a specific range and maintaining the ratio L1/(L1+L2) between 1.3-10, the cooling performance is maximized while minimizing the impact on insulating layer thickness and coil winding capacity.
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
The insulated wire design improves cooling efficiency by allowing direct contact with the cooling medium, resulting in faster and more effective heat dissipation.
Implementation Method 1
a cooling channel can be formed between wires, thus the cooling medium is in direct contact with the insulated wire, thereby improving the heat conduction efficiency
Data Source
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AI summary
The present invention discloses an insulated wire and a preparation method thereof, a coil and an electronic/electrical device, belonging to the technical field of insulated wires. The insulated wire comprises a conductor and an insulating layer arranged at the periphery of the conductor, wherein the cross section of the conductor takes the shape of a rectangle, a sunken part is formed in the insulating layer on at least one surface of the conductor, the sunken part extends in the whole length direction of the insulating layer, a convex part is formed in the left and right sides of the sunken part, the distance between the bottommost part of the sunken part and the surface of the conductor is L1, L1 is 50µm-300µm, the distance between the bottom of the sunken part and the highest point of the convex part is L2, and the value that L1 is divided by the sum of L2 and L1 is greater than 1.3 and smaller than or equal to 10. According to the insulated wire provided by the present invention, a channel for introducing a cooling medium can be formed in the insulated wire, and the cooling medium is in direct contact with the wire, being large in contact area, rapid in cooling speed, and high in efficiency.