Perforated Insulated Preformed Coil for Electric Machine Cooling
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Solution Overview
Problem
Existing electric machine coils face challenges in achieving sufficient electrical insulation while maintaining effective cooling, as insulation materials act as thermal insulators, increasing thermal resistance and limiting heat transfer from the conductive strands to the cooling medium.
Innovation Solution
The coils are redesigned with an insulating body that includes perforations or flow channels, allowing direct or near-contact with a coolant to enhance heat transfer, while maintaining electrical insulation and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation materials are used to provide electrical insulation for the coil windings, then electrical insulation is sufficient, but thermal resistance increases and heat transfer is limited
Solution Approach 1:
The insulating body is designed with a porous structure containing multiple flow channels that allow coolant circulation. This porous configuration enables the material to provide electrical insulation while simultaneously facilitating thermal management through internal coolant flow paths, resolving the contradiction between insulation and heat dissipation.
Solution Approach 2:
The solution transitions from external cooling to internal cooling by embedding flow channels within the insulating body itself. This dimensional integration allows the insulating body to perform dual functions: electrical insulation on its outer surface and thermal conduction via internal coolant flow, eliminating the trade-off between insulation and cooling.
2Ease of manufacture
If a preformed coil with insulation is manufactured separately, then assembly is facilitated, but cooling effectiveness is reduced due to insulation barriers
Solution Approach 1:
The insulating body is designed to perform multiple functions simultaneously: providing electrical insulation for the coil windings, providing structural support for the preformed coil shape, and enabling internal cooling through integrated flow channels. This multi-functionality resolves the contradiction between ease of assembly and cooling effectiveness.
Solution Approach 2:
The solution merges the insulating body and cooling system into a single integrated component. The flow channels are embedded within the insulating body itself, combining the electrical insulation function with the thermal management function, allowing the preformed coil to be assembled as one unit while maintaining effective cooling.
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 reduces thermal resistance, enabling improved heat transfer and cooler operating temperatures, thereby increasing power density and efficiency of the electric machine.
Implementation Method 1
at least a portion of the insulating body includes perforations that allow a coolant to penetrate into the insulating body to cool the coil during use of the electric machine
Data Source
AI summary
A coil for an electric machine including a conductive strand having a first end, a second end, and a plurality of windings between the first and second ends and an electric insulating body within which the conductive strand is at least partially encased, wherein at least a portion of the insulating body includes perforations that allow a coolant to penetrate into the insulating body to cool the coil during use of the electric machine. A method of making the coil includes molding or printing the insulating body about the conductive strand so as to have perforations therein.