PCM Wax Mixture Cooling Casing for EV Motor Temperature Transients
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Solution Overview
Problem
High-performance electric vehicles require effective temperature regulation to manage rapid temperature transients, but existing cooling systems, especially those using liquid cooling, are inefficient and prone to issues like size, safety, and emissions, and traditional PCM waxes have limitations such as low heat conductivity and viscosity problems, especially when used in electric motors with varying operational temperatures.
Innovation Solution
A composition of at least two PCM waxes with different melting temperatures, ranging from 60 to 120 °C, is used to accumulate latent heat within a hollow cooling casing, allowing for efficient temperature control and stability across a broad range, reducing the need for traditional liquid cooling systems and minimizing material degradation over cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional liquid cooling systems are used for electric machines, then cooling function is provided, but the system size increases, safety issues arise, and consumption/emissions problems occur
Solution Approach 1:
The invention extracts the cooling function from complex liquid cooling systems with pumps, channels, and refrigerants, and implements it using a simple PCM-based passive cooling system that relies on phase change material properties alone, eliminating the need for complex mechanical components
Solution Approach 2:
The PCM cooling system is self-regulating through the natural phase change process of the material, which automatically absorbs heat during melting without requiring external control systems, pumps, or active management, making the system self-service and highly reliable
2Use of energy by moving object
If single PCM wax is used for heat accumulation, then latent heat storage is achieved, but the temperature range coverage is limited and performance degrades after multiple cycles
Solution Approach 1:
The invention uses composite materials by combining multiple PCM waxes with different melting points into a single cooling composition, creating a multi-component system that covers a broader temperature range (60-120°C) while maintaining stable performance over multiple thermal cycles
Solution Approach 2:
The invention changes the physical parameters of the cooling system by selecting waxes with specific melting points (e.g., C20-C30 range around 60-75°C, C30-C40 range around 76-85°C, C40-C50 range around 86-102°C) to optimize the temperature coverage and match the operational temperature profile of electric machines
3Power
If high-performance electric motors are used, then vehicle performance increases, but temperature transients become more rapid and irregular, requiring more effective cooling
Solution Approach 1:
The invention optimizes the thermal response parameters by carefully selecting the composition and proportions of different waxes to match the rapid and irregular temperature transients characteristic of high-performance electric motors, ensuring effective cooling across varying operational conditions
Solution Approach 2:
The multi-wax composite composition provides enhanced thermal management capability for high-power motors by combining materials with different phase change temperatures, creating a progressive cooling effect that handles both rapid transients and sustained thermal loads
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 PCM wax mixture effectively manages temperature transients in electric vehicle motors by maintaining a stable temperature range, optimizing performance and reducing the risk of material breakdown, even after multiple cycles, while providing a cost-effective and compact cooling solution.
Implementation Method 1
Latent heat storage is based on the heat absorbed or released when a material undergoes a phase change from solid to liquid or from liquid to gas (and vice versa), without significant changes in temperature
Implementation Method 2
a composition comprising a mixture of at least two waxes belonging to the class of phase change materials (PCM waxes) as an element for accumulating latent heat
Data Source
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AI summary
The present invention relates to the use of a composition comprising a mixture of at least two waxes belonging to the class of phase change materials (PCMs) as an element for accumulating latent heat in an electric machine, preferably for automotive use. In one embodiment, the composition is contained inside a hollow cooling casing of an electric machine, preferably for automotive use. The present invention also relates to a method for producing a hollow cooling casing containing said composition and for cooling an electric machine which comprises the use of said cooling casing.