Open Coil Winding Direct Cooling With Sealed Electrical Isolation
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Solution Overview
Problem
Existing electric machines in the aviation sector face challenges in achieving high performance while minimizing weight and size, particularly with the increasing use of 800 V systems, which complicates cooling and insulation design.
Innovation Solution
An electric machine design featuring a flow path for coolant fluid that directly cools coils within a sealed housing, using insulation and electrical connections to allow conductive coolant fluids, enabling effective cooling without external heat sinks and additional re-cooling systems, and utilizing external environmental fluids like air or water for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling systems with external heat sinks and interconnected cooling circuits are used, then reliable cooling is achieved, but device complexity and weight increase
Solution Approach 1:
The patent extracts the cooling function directly to the coil level by placing coolant flow paths through the coil windings themselves, eliminating the need for external heat sinks and interconnected cooling circuits. The coolant flows directly through channels in the coil structure, providing cooling at the heat source without requiring complex external cooling infrastructure.
Solution Approach 2:
The cooling function is merged with the coil structure by integrating flow paths directly into the coil windings. The coil serves dual purposes: electrical function and heat transfer surface. This integration eliminates separate cooling components and reduces overall system complexity while maintaining effective cooling.
2Temperature
If electrically conductive coolant fluids are used for direct cooling, then cooling efficiency improves, but insulation requirements and safety concerns increase
Solution Approach 1:
The coil structure is segmented into electrically isolated sections with coolant flow paths positioned between winding layers or within structural elements. This segmentation creates natural electrical insulation barriers while maintaining thermal contact with the coolant, allowing conductive coolants to be used without compromising electrical safety.
Solution Approach 2:
The patent introduces non-conductive structural elements or insulation layers as intermediaries between the conductive coolant and the electrical windings. These intermediaries transfer heat from the windings to the coolant while preventing electrical conduction, enabling the use of conductive coolants with maintained electrical isolation.
3Reliability
If protective housings and sealed enclosures are added to protect coils from environmental contaminants, then reliability improves, but weight and device complexity increase
Solution Approach 1:
The coil structure is designed to perform multiple functions simultaneously: electrical function, heat transfer surface for cooling, and environmental protection barrier. The same structural elements that provide mechanical support and cooling pathways also serve as protection from contaminants, eliminating the need for separate protective housings and reducing overall weight.
4Temperature
If external cooling systems and re-cooling circuits are implemented, then temperature control is improved, but system complexity and weight increase
Solution Approach 1:
The cooling system is designed to utilize external environmental resources (air, water) directly as coolant sources without requiring complex re-cooling circuits or external heat sinks. The coil structure with integrated flow paths enables direct heat exchange with the environment, allowing the system to self-regulate temperature using freely available environmental cooling resources.
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
This design achieves high-performance electric machines with efficient cooling, reduced weight, and simplified construction by eliminating the need for external cooling systems and protective housings, while maintaining secure insulation against environmental contaminants.
Implementation Method 1
the flow path extends through the at least one coil
Implementation Method 2
the coil (13A-13C) is provided with an insulation layer (133), by which the coil conductor (132A-132C) is at least partially enclosed
Data Source
AI summary
An electric machine includes a flow path for coolant fluid, a housing sealed off in relation to the flow path, a power supply unit, and at least one coil. The at least one coil includes at least one insulated section and contacts, wherein the contacts of the at least one coil are electrically connected inside the housing to contacts of the power supply unit and the at least one insulated section is arranged in the flow path.