Phase-Change Cooled Coil Conductor for Transient Heat Peaks

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Solution Overview

Problem

Existing methods for manufacturing electric conductors with integrated phase change materials are complex and unsuitable for small cross-sectional areas, leading to increased size and weight, and fail to effectively manage high-current transient heat peaks in electric machines.

Innovation Solution

A method involving electrolytic deposition of electrically conductive material onto a heat sink preform containing phase change material, allowing for a conductor with variable cross-section and simplified manufacturing, including insulation and volume adjustment steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If natural convection cooling with finned heat sink is used, then heat dissipation area is increased, but overall size and mass of the machine increase

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidmass of cooling system

Core Design Contradiction:

Loss of energyVSWeight of stationary object

Solution Approach 1:

The phase change material is embedded within hollow conductors that are already present in the electric machine winding, creating a nested structure where the cooling function is integrated inside the existing conductor structure. This eliminates the need for external finned heat sinks while maintaining effective heat dissipation through the phase change material's latent heat absorption during transient high-current operations.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Loss of energy

If forced convection cooling with fan is added, then heat exchange is improved, but overall size increases and additional failure sources are introduced

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidcooling system complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The phase change material provides passive cooling without requiring external fans or active control systems. The material automatically absorbs heat during transient high-current operations through its phase change process, making the cooling system self-regulating and eliminating mechanical components that could fail.

Inventive Principle:

Principle #25Self-service

3Loss of energy

If liquid forced cooling with circulating channels is implemented, then heat dissipation is improved, but overall size increases, mass increases, and maintenance intervals are reduced

Engineering Contradiction:

Improveheat dissipation capacityVSAvoidmass of cooling system

Core Design Contradiction:

Loss of energyVSWeight of stationary object

Solution Approach 1:

The cooling function is extracted from the liquid circulation system and implemented instead through solid phase change material embedded in the conductors. This eliminates the need for liquid circulation pumps, channels, and external exchangers, significantly reducing mass and maintenance requirements while maintaining effective heat dissipation during transient operations.

Inventive Principle:

Principle #2Taking out (Extraction)

4Power

If conductor cross-sectional area is increased to reduce electric resistance, then power capability is improved, but mass and overall size increase

Engineering Contradiction:

Improveelectric power capabilityVSAvoidmass of conductor

Core Design Contradiction:

PowerVSWeight of stationary object

Solution Approach 1:

The approach changes the thermal management parameter from relying on large conductor cross-sections for heat dissipation to using phase change material's latent heat absorption capability. This allows conductors to be optimized for electrical performance without being oversized for thermal management, as the phase change material handles the transient heat loads independently.

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

Facilitates efficient heat management during high-current transients by simplifying manufacturing and reducing conductor size and weight, while maintaining conductivity and sealing integrity.

Implementation Method 1

a heat sink comprising a phase change material inside said conductor element

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

the phase change material is capable of changing physical state between the solid state and the liquid state within a given temperature range

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 3

a sub-step of inserting the heat sink preform into an electrolytic solution of the electrically conductive material, an electrodeposition substep for depositing the electrically conductive material onto the heat sink preform

Methodology Applied

Scientific EffectElectrodeposition: Electrodeposition

Data Source

PatentUS12562611B2Electrical conductor cooled by phase change material and method for the manufacture thereof

Publication Date: 2026.02.24 SAFRAN SA

AI summary

A method for manufacturing a conductor of a winding of a coil, includes manufacturing a heat-sink preform including a phase-change material, depositing a conductive element by layer deposition of electrically conductive material on the heat-sink preform, including inserting the heat-sink preform into an electrolytic solution of the electrically conductive material, and; electrodeposition for depositing the electrically conductive material on the heat-sink preform.