Integrated Motor Cooling Conduits for Lightweight Aircraft Propulsion

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Solution Overview

Problem

Electric motors and propulsion systems for aircraft require cooling systems that add weight and increase installation complexity due to external components like heat exchangers and pumps, reducing power density and efficiency.

Innovation Solution

An integrated cooling system within the electric motor and propulsion system, featuring a motor cooling conduit with a thermally conductive relationship and a pump or compressor coupled to the drive shaft, circulates cooling fluid through the motor and casing assembly conduits, eliminating the need for external components and enhancing thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If external cooling components (heat exchanger, pump, pipes, hoses) are used to cool the electric motor, then the motor can be cooled effectively, but the weight increases and power density decreases

Engineering Contradiction:

Improvemotor cooling effectivenessVSAvoidcooling system weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The cooling system components (conduits, pump, heat exchanger) are integrated into the electric motor assembly itself rather than being external separate components. The motor housing incorporates cooling conduits that circulate fluid through the motor, and the pump is driven by the motor's own drive shaft, merging multiple functions into a single unified structure that reduces overall weight while maintaining cooling effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The motor assembly serves multiple functions: it generates mechanical power while also housing and driving the cooling system. The drive shaft not only transmits mechanical power but also drives the pump for cooling fluid circulation. The motor housing serves both structural purposes and contains the cooling conduits, creating a multi-functional integrated system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If external cooling components (heat exchanger, pump, pipes, hoses) are used to cool the electric motor, then the motor can be cooled effectively, but the installation complexity increases

Engineering Contradiction:

Improvemotor cooling effectivenessVSAvoidinstallation complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If the motor is made more compact to improve power density, then the power density increases, but thermal management becomes more challenging

Engineering Contradiction:

Improvemotor compactnessVSAvoidthermal management difficulty

Core Design Contradiction:

Weight of moving objectVSTemperature

Solution Approach 1:

The cooling conduits are nested within the motor housing and windings, with the pump nested within the motor assembly and driven by the drive shaft. The heat exchanger is integrated into the motor structure, creating a nested configuration where cooling components are embedded within the motor itself, enabling effective thermal management in a compact form factor.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 integrated cooling system enhances power density, efficiency, and simplifies installation by reducing weight and auxiliary components, allowing for more compact and lighter electric motors with improved thermal management.

Implementation Method 1

the motor cooling conduit has a thermally conductive relationship with the at least a portion of the electric motor

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the casing assembly conduit has a thermally conductive relationship with an external surface of the casing assembly

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a pump or compressor operably coupled to the drive shaft and configured to circulate the cooling fluid through the motor cooling conduit and the casing assembly conduit

Methodology Applied

Scientific EffectPumping: Pump

Data Source

PatentUS11885229B2Electric motor having an integrated cooling system and methods of cooling an electric motor

Publication Date: 2024.01.30 GENERAL ELECTRIC CO

AI summary

The present disclosure pertains to electric machines such as electric propulsion systems for aircraft that integrated cooling systems, and methods of cooling such an electric machine. Exemplary electric machines include an electric motor that has a stator, a rotor, and a drive shaft operably coupled to the rotor. Exemplary electric machines further include a motor cooling conduit that defines a pathway for conveying a cooling fluid through or around at least a portion of the electric motor, a casing assembly that circumferentially surrounds at least a portion of the electric motor, a casing assembly conduit integrally formed within at least a portion of the casing assembly which defines a pathway for conveying the cooling fluid through the at least a portion of the casing assembly, and a pump or compressor operably coupled to the drive shaft and configured to circulate the cooling fluid through the motor cooling conduit and the casing assembly conduit.