Insulating Heat Sink Shells for Motor and Electronics Cooling
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Solution Overview
Problem
Existing electric motors are prone to overheating and damage, and integrating electronic systems without proper insulation can lead to malfunctions due to different on-board voltages and the need for effective cooling of both systems.
Innovation Solution
An electric motorization device with a heat sink interposed between the electric motor and electronic system, featuring insulated shells to prevent electrical interference and a shared cooling circuit for both components, using composite and insulating materials for the shells and a cooling fluid passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If glycol water is used in the cooling circuit, then the motor can be cooled, but electrical conductivity causes integration of electronic system to be impossible
Solution Approach 1:
The cooling system is segmented into two separate circuits: a first cooling circuit for the electric motor using electrically conductive coolant (glycol water), and a second cooling circuit for the electronic system using electrically insulating coolant. This segmentation allows each circuit to use the most appropriate coolant type for its specific requirements, resolving the contradiction between cooling efficiency and electrical insulation.
Solution Approach 2:
An intermediate heat exchanger is introduced between the two cooling circuits. This heat exchanger allows thermal energy transfer from the motor cooling circuit to the electronic system cooling circuit without allowing direct contact between the conductive and insulating coolants, thus maintaining electrical insulation while achieving cooling of both systems.
2Temperature
If aluminum heat sink is used, then cooling is achieved, but electrical conductivity creates safety issues with electronic system integration
Solution Approach 1:
The electrical property parameter of the coolant is changed from conductive (in the motor circuit) to insulating (in the electronic system circuit). This parameter change allows the cooling function to be maintained while eliminating the electrical conductivity hazard when working with electronic systems.
Solution Approach 2:
The heat exchanger acts as an intermediary that transfers thermal energy without allowing electrical conduction. This intermediary enables the aluminum heat sink to perform its cooling function while preventing direct electrical contact between the conductive motor environment and the electronic system.
3Reliability
If cooling system is integrated, then overheating is prevented, but electrical isolation between different voltage systems becomes difficult
Solution Approach 1:
The integrated cooling system is segmented into separate cooling circuits for different voltage systems. The first cooling circuit serves the motor (higher voltage) and the second cooling circuit serves the electronic system (lower voltage), with electrical isolation maintained between them through the use of insulating coolant and heat exchanger architecture.
Solution Approach 2:
The heat exchanger serves as an intermediary structure that enables thermal coupling between the two voltage systems while maintaining electrical isolation. This intermediary allows the cooling systems to be functionally integrated for overheating prevention while preserving the necessary electrical isolation for safety.
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
Ensures electrical insulation and efficient cooling of both the electric motor and electronic system, preventing overvoltages and malfunctions while optimizing operational longevity.
Implementation Method 1
configured to allow a heat exchange between a cooling fluid and the electronic system
Implementation Method 2
a heat sink interposed between the electric motor and the electronic system, said heat sink being intended to cool the electronic system
Implementation Method 3
The first shell and the second shell are each constituted of a material configured to guarantee an electrical insulation
Data Source
AI summary
An electric motorization device including an electric motor, an electronic system comprising power electronic elements, and a heat sink that is intended to cool the electronic system. The heat sink comprises a first shell configured to allow heat exchange between a coolant fluid and the electronic system, and a second shell configured to prevent heat exchange between the coolant fluid and the electric motor. The first shell and the second shell together define a cavity configured to allow the passage of the coolant fluid. The first shell and the second shell are each made of a material configured to ensure electrical insulation, in particular between the electronic system, the coolant fluid and the electric motor.