Insulating Busbar Assembly With Integrated Cooling Channels
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Solution Overview
Problem
Existing cooling systems for electric machines, particularly those with stators, face challenges in efficiently dissipating heat loss due to complex and difficult-to-produce cooling water supply lines, which often require awkwardly curved channels that are hard to manufacture using casting technology.
Innovation Solution
An insulating device with integrated cooling medium channels made of electrically insulating plastic material, such as Luvocom 1-8259 or Tecacomp PA 66 TC 3923, that embeds busbars and incorporates molded cooling channels, allowing for simplified production and efficient heat dissipation without the need for additional components or separate connection pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate cooling water supply lines with curved channels are used, then cooling function is achieved, but manufacturing complexity and production difficulty increase significantly
Solution Approach 1:
The patent merges the cooling water supply line with the insulating device into a single integrated component. The cooling channels are directly formed within the insulating device body, eliminating the need for separate curved supply lines and reducing the number of parts. This integration simplifies manufacturing while maintaining the cooling function.
Solution Approach 2:
The insulating device is designed to perform multiple functions simultaneously: electrical insulation, mechanical support for busbars, and cooling water guidance. By incorporating cooling channels directly into the insulating device, it becomes a multi-functional component that replaces both the insulating structure and the separate cooling supply line.
2Device complexity
If multiple separate components are used for insulation and cooling, then functional requirements are met, but the number of components and assembly complexity increase
Solution Approach 1:
The patent combines multiple functional components (insulating structure, busbar support, cooling supply line) into a single integrated insulating device. This reduction in component count simplifies assembly while improving reliability by eliminating potential failure points at connection interfaces between separate parts.
3Ease of manufacture
If cooling channels are integrated into the insulating device, then manufacturing is simplified and components are reduced, but the insulating material must satisfy both electrical and thermal requirements
Solution Approach 1:
The patent employs composite material construction, combining materials with different properties within the insulating device. The insulating device body uses electrically insulating material, while the integrated cooling channels are formed with thermally conductive material to efficiently guide cooling water. This composite approach allows each material to optimize its specific function while being manufactured as an integrated component.
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 reduces the temperature of busbars, minimizes ohmic resistance, and provides reliable electrical insulation while simplifying the production of housing parts, reducing the number of components and ensuring leak-free cooling medium guidance, thus achieving efficient and space-saving cooling.
Implementation Method 1
dissipate heat loss from a stator of an electric machine
Implementation Method 2
efficient heat dissipation
Implementation Method 3
embeds busbars and incorporates molded cooling channels, allowing for simplified production and efficient heat dissipation without the need for additional components or separate connection pieces
Data Source
Figure 1
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AI summary
The invention relates to an insulating device (40) having integrated cooling medium channels (44, 46), comprising an insulating body (74) made of a plastic material (52, 60), in which conductor rails (18, 20, 22) are accommodated. The cooling medium channels (44, 46) are integrated into the plastic material (52, 60) of the insulating body (74).