Electric Motor Housing With Oscillating Heat Pipe Cooling
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Solution Overview
Problem
Existing electric motors face challenges in efficiently managing waste heat due to poor thermal conductivity of stator cores, leading to overheating and potential damage, especially in high-power and extreme thermal environments, with traditional thermal management systems adding complexity and mass.
Innovation Solution
Integration of an embedded oscillating heat pipe (OHP) within the motor housing and stator core, utilizing 3D printing to create a monolithic structure with serpentine channels for heat transport and rejection, enhancing thermal conductivity and maintaining the motor's form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal management systems are added to electric motors, then heat dissipation capability is improved, but device complexity and mass increase
Solution Approach 1:
The patent merges the thermal management function with the motor housing structure by integrating heat pipes directly into the housing design. The heat pipes are embedded within the housing walls, combining the structural support function with the heat dissipation function, thereby improving heat dissipation capability without increasing device complexity
Solution Approach 2:
The motor housing serves multiple functions: it provides structural support, contains the motor components, and simultaneously acts as a heat dissipation system through integrated heat pipes. This multi-functionality eliminates the need for separate thermal management subsystems, reducing overall system complexity while maintaining effective heat dissipation
2Temperature
If traditional thermal management systems are added to electric motors, then heat dissipation capability is improved, but mass of the motor increases
Solution Approach 1:
By combining the heat dissipation function with the existing motor housing structure through integrated heat pipes, the patent eliminates the need for additional separate thermal management components. The heat pipes are embedded within the housing walls, utilizing the existing structural mass rather than adding new mass, thereby improving heat dissipation capability without increasing motor mass
Solution Approach 2:
The motor housing is designed to serve as both a structural component and a thermal management system. The heat pipes are integrated into the housing, making the housing a multi-functional component that supports both mechanical and thermal management functions, thus avoiding additional mass from separate thermal management systems
3Power
If stator core material with poor thermal conductivity is used, then magnetic performance is maintained, but heat transport capability deteriorates
Solution Approach 1:
The patent introduces heat pipes as an intermediary thermal conduction path between the stator windings and the motor housing. The heat pipes are embedded in the housing walls adjacent to the stator, providing a high thermal conductivity pathway that mediates the heat transfer from the poor thermal conductivity stator core material to the external environment, thereby improving heat transport capability without changing the stator core material
Solution Approach 2:
The patent replaces reliance on thermal conduction through the stator core material with a phase-change heat pipe system. Instead of depending on the thermal conductivity of the magnetic core material, the system uses heat pipes with working fluid phase changes to transport heat away from the stator windings, effectively substituting a mechanical thermal conduction approach with a thermodynamic heat transfer mechanism
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
Effectively transports heat away from the stator windings to a secondary heat sink, preventing overheating and maintaining motor performance across various thermal conditions while reducing complexity and mass.
Implementation Method 1
embedded oscillating heat pipe (OHP) within the motor housing and stator core
Implementation Method 2
embedded oscillating heat pipe (OHP) within the motor housing and stator core
Implementation Method 3
current conducted through the stator windings (126) may cause resistive heating of the stator windings (126)
Data Source
AI summary
Systems and methods for integrating a heat exchanger in an electric motor (EM) system that includes a stator and a rotor are presented. An oscillating heat pipe (OHP) is provided within a housing of the EM system. The OHP includes channel segments with a sealed working fluid. According to another aspect, channel segments formed within a core of the stator communicate with the channel segments of the housing to provide an OHP. According to another aspect, the core of the stator includes an OHP. According to another aspect, the housing includes protruding structures with embedded channel segments. According to one aspect, the protruding structures include a plurality of fins. According to yet another aspect, the protruding structures are in contact with a fluid coolant that flows in a cavity of a structure coupled to the housing.