Integrated Motor Stator Cooling With Phase-Change Materials
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Solution Overview
Problem
Traditional electric motors face thermal management limitations due to internal thermal resistance and heat dissipation constraints, leading to weight and volume additions from conventional cooling methods like natural convection and liquid cooling, which are undesirable for high-power-density applications such as aviation systems.
Innovation Solution
Incorporating phase-change material elements within the stator windings, flow channels, and headers of electric motors to enhance thermal interaction and manage transient heat loads without increasing system volume or weight, using materials like paraffin-based wax, salt hydrates, and metallic-based materials for effective heat absorption and dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (natural convection or liquid cooling jackets) are used to manage heat in electric motors, then heat dissipation capability is improved, but motor volume and weight increase due to the addition of cooling jackets
Solution Approach 1:
The patent combines the cooling function with the existing stator structure by integrating phase-change material elements directly into the stator windings, flow channels, and headers. This merging eliminates the need for separate cooling jackets, achieving heat dissipation improvement without increasing motor weight or volume.
Solution Approach 2:
The patent utilizes phase-change materials (such as paraffin-based wax, salt hydrates, and metallic-based materials) that absorb excess heat during phase transitions (e.g., solid to liquid). These materials are strategically placed within the stator to capture transient heat loads during high-power operations, then slowly dissipate the stored heat through conventional cooling channels, thereby improving thermal management without adding external cooling components.
2Temperature
If conventional cooling methods are used to manage heat in electric motors, then heat dissipation capability is improved, but motor volume increases due to the addition of cooling jackets
Solution Approach 1:
The cooling function is merged with the existing stator structure by integrating phase-change material elements directly into the stator windings, flow channels, and headers. This integration achieves effective heat dissipation without requiring additional external cooling jackets, thereby avoiding volume increase.
Solution Approach 2:
The phase-change material elements are nested within the existing stator components (windings, flow channels, headers), utilizing the internal space of the stator structure. This nesting approach allows the cooling function to be embedded without increasing the overall motor volume.
3Temperature
If internal thermal resistance is reduced to improve heat dissipation, then temperature control is improved, but manufacturing complexity increases due to modifications in stator structure
Solution Approach 1:
The patent applies phase-change material elements at specific locations within the stator where heat generation is most intense (e.g., within windings, at flow channels, and in headers). This localized application improves temperature control in critical areas without requiring comprehensive structural modifications throughout the entire stator, thereby limiting the increase in manufacturing complexity.
Solution Approach 2:
The patent modifies thermal parameters (such as thermal conductivity and heat capacity) by introducing phase-change materials at strategic locations within the stator. These parameter changes improve temperature control by enhancing heat absorption and dissipation capabilities, while the modular integration approach keeps manufacturing complexity manageable.
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 integration of phase-change materials allows for improved thermal efficiency and increased load capacity during high-power operations, such as takeoff conditions, while maintaining a lightweight and compact motor design by absorbing excess heat and slowly dissipating it through conventional cooling channels.
Implementation Method 1
one or more phase-change material elements arranged to thermally interact with at least one of the first header, the second header, the one or more flow channels, and the plurality of windings
Implementation Method 2
the integration of phase-change materials allows for improved thermal efficiency and increased load capacity during high-power operations, such as takeoff conditions, while maintaining a lightweight and compact motor design by absorbing excess heat
Implementation Method 3
a plurality of windings fluidly connected to the first header and the second header to receive a cooling fluid passing from the first header to the second header along one or more flow channels
Data Source
AI summary
Electric motors and stators thereof are described. The stators of the electric motors include a first header, a second header fluidly connected to the first header, a plurality of windings fluidly connected to the first header and the second header to receive a cooling fluid passing from the first header to the second header along one or more flow channels, and one or more phase-change material elements arranged to thermally interact with at least one of the first header, the second header, the one or more flow channels, and the plurality of windings.