Layered Rotor Displacement Body With Cooling Channels for Heat Dissipation

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Solution Overview

Problem

Existing rotor windings in externally excited synchronous machines suffer from high loss density and temperature due to high current, limiting continuous output, with existing cooling methods failing to efficiently dissipate heat, particularly in the rotor center.

Innovation Solution

A displacement body for the rotor is designed as a layered stack of conductive and insulating sheets, preferably made of aluminum, with integrated cooling channels, to enhance thermal conductivity and improve heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a plastic displacement body with integrated cooling channel is used, then the cooling structure is simplified and manufacturing is easier, but the thermal conductivity is low and heat dissipation efficiency deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat dissipation efficiency

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The displacement body is constructed as a composite structure combining a plastic component (for structural function and ease of manufacture) with a metal insert (for thermal conduction). The metal insert is integrated into the plastic displacement body, creating a hybrid material system that simultaneously achieves easy manufacturing and high thermal conductivity for effective heat dissipation from the rotor winding.

Inventive Principle:

Principle #40Composite materials

2Temperature

If a metal displacement body is used, then thermal conductivity and heat dissipation are improved, but eddy current losses increase

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoideddy current losses

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The displacement body is segmented into functionally distinct components: a plastic matrix providing structural support and electrical insulation, and a metal insert providing thermal conduction. This segmentation allows each material to perform its optimal function while avoiding the drawbacks of using a single material throughout the entire structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal material is localized specifically to the regions requiring high thermal conductivity (the cooling channel and adjacent areas), while the plastic material occupies regions where structural support and electrical insulation are prioritized. This local differentiation of material properties optimizes overall system performance.

Inventive Principle:

Principle #3Local quality

3Power

If the rotor winding is perfused with high current to generate strong magnetic field, then the magnetic field strength is improved, but the loss density and temperature increase

Engineering Contradiction:

Improvemagnetic field strengthVSAvoidloss density

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The metal insert in the displacement body acts as a thermal intermediary, providing a low thermal resistance pathway between the rotor winding (heat source) and the cooling medium. This intermediary structure efficiently transfers the heat generated by high current operation to the cooling system, enabling sustained high power operation without excessive temperature rise.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enhances heat transfer from the rotor winding to the cooling medium, increasing the continuous output of the electric machine while maintaining high efficiency by reducing thermal resistance and avoiding eddy current losses.

Implementation Method 1

a low thermal resistance between the winding and the cooling channel is required

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

designed as a layered stack of conductive and insulating sheets, preferably made of aluminum, with integrated cooling channels, to enhance thermal conductivity and improve heat dissipation

Methodology Applied

Scientific EffectThermal conductivity enhancement: Conduction (thermal)

Data Source

PatentUS12418208B2Displacement body for a rotor and correspondingly configured rotor

Publication Date: 2025.09.16 DR ING H C F PORSCHE AG

AI summary

A displacement body for a rotor, wherein the displacement body is configured to be inserted into a slot between two respective rotor teeth, includes a main part, a head part adjoining the main part, and at least one cooling channel, which extends through the displacement body in a depth direction. The head part includes a region flaring towards an outside of the displacement body. The displacement body is configured as a layer stack, which, in the depth direction, includes at least two adjoining layers.