Motor Controller Cooling via Sealed Two-Phase Cold Plate

Solution Overview

Problem

Existing motor controllers in aircraft engines face challenges in cooling without liquid coolant, as they generate significant heat and require efficient heat dissipation methods, especially in applications where only air cooling is available.

Innovation Solution

A two-phase cooling system using a liquid-cooled cold plate with a sealed fluid that cycles between liquid and vapor, combined with air cooling, where heat-generating components are positioned to maximize heat transfer and air flow channels enhance convective and conductive cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a liquid cooled motor controller is used, then heat dissipation efficiency is improved, but system weight and complexity increase due to liquid coolant requirements

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidsystem weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The invention changes the cooling parameter from liquid-based convection to phase-change-based heat transfer. The cold plate uses a sealed two-phase fluid system that absorbs heat through phase change (liquid to vapor) directly at the heat source, eliminating the need for liquid coolant circulation systems and associated weight

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention directly applies phase transition principles by using a two-phase cold plate where a sealed fluid cycles between liquid and vapor phases to transfer heat. The phase change occurs within the cold plate structure itself, providing high heat dissipation efficiency without requiring external liquid coolant systems

Inventive Principle:

Principle #36Phase transitions

2Temperature

If a liquid cooled motor controller is used, then heat dissipation efficiency is improved, but device complexity increases due to liquid cooling system requirements

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The invention uses phase transition of a sealed two-phase fluid within the cold plate to achieve heat dissipation. The fluid naturally cycles between liquid and vapor phases through heat absorption and release, eliminating the need for pumps, valves, and complex liquid cooling infrastructure

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The two-phase cold plate system is self-regulating through natural phase change cycles. The sealed fluid automatically absorbs heat when liquid and releases heat when vapor, without requiring external control systems or complex liquid cooling infrastructure

Inventive Principle:

Principle #25Self-service

3Weight of moving object

If air cooling is used instead of liquid cooling, then system weight and complexity are reduced, but heat dissipation efficiency decreases

Engineering Contradiction:

Improvesystem weightVSAvoidheat dissipation efficiency

Core Design Contradiction:

Weight of moving objectVSTemperature

Solution Approach 1:

The invention uses phase transition of a sealed two-phase fluid within the cold plate to achieve heat dissipation. The fluid naturally cycles between liquid and vapor phases through heat absorption and release, eliminating the need for pumps, valves, and complex liquid cooling infrastructure

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The invention changes the cooling parameter from liquid-based convection to phase-change-based heat transfer. The cold plate uses a sealed two-phase fluid system that absorbs heat through phase change (liquid to vapor) directly at the heat source, eliminating the need for liquid coolant circulation systems and associated weight

Inventive Principle:

Principle #35Parameter changes

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

Enables efficient cooling of motor controllers in applications without liquid coolant, reducing weight and cost by optimizing heat transfer and allowing adaptation from liquid-cooled to air-cooled systems, while maintaining effective heat dissipation.

Implementation Method 1

a liquid-cooled cold plate with a sealed fluid that cycles between liquid and vapor

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

A two-phase cooling system using a liquid-cooled cold plate with a sealed fluid that cycles between liquid and vapor

Methodology Applied

Scientific EffectTwo-phase cooling: Two-Phase Flow

Implementation Method 3

air flow channels enhance convective and conductive cooling

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

heat-generating components are positioned to maximize heat transfer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3102013B1System and method of alternate cooling of a liquid cooled motor controller

Publication Date: 2020.05.06 HAMILTON SUNDSTRAND CORP

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AI summary

A motor controller (20) is provided including a motor controller housing (22) an air inlet and an air outlet. A plurality of heat generating elements (24) is disposed within the motor control housing (22). A cooling system (30) includes a cooling device (32) having a fluid sealed therein arranged within the motor control housing (22). The plurality of heat generating elements is cooled by conduction to the cooling device (32) and by convection from an air flow between the air inlet and the air outlet.