Stator Winding Subassembly With Embedded Conductor Tracks for Heat Dissipation
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Solution Overview
Problem
Existing electrical components, such as stators, face challenges with large installation space requirements and significant heat generation, leading to inefficient operation and high power consumption.
Innovation Solution
A conductor track structure is embedded in an electrically insulating support structure composed of stacked plate-like parts, with overlapping passages for conductor sections, using highly thermally conductive materials like aluminum nitride, and incorporating cooling channels for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional winding heads with large size are used to connect conductor sections, then electrical connections can be established, but installation space is excessively occupied and heat generation increases
Solution Approach 1:
The support structure is divided into multiple plate-like parts stacked in the axial direction, with conductor track structures embedded in each plate. This segmentation allows the winding head to be compact while maintaining multiple connection points for reliable electrical connections between conductor sections.
Solution Approach 2:
Conductor sections are connected not only in the radial direction but also in the axial direction through stacked support structure plates. This multi-dimensional arrangement reduces the radial space requirement while maintaining connection reliability through multiple contact points.
2Loss of energy
If conventional insulating materials are used in the support structure, then electrical insulation is provided, but heat dissipation is insufficient leading to high power consumption
Solution Approach 1:
The support structure uses composite material design where aluminum nitride ceramic plates (high thermal conductivity) are stacked with conductor track structures embedded. This composite approach provides both electrical insulation and superior heat dissipation, reducing power loss while managing temperature effectively.
Solution Approach 2:
The material parameter of the support structure is changed from conventional insulating materials to aluminum nitride ceramic with high thermal conductivity (100-400 W/mK). This parameter change enables efficient heat dissipation while maintaining electrical insulation properties, directly reducing power consumption and temperature.
3Temperature
If aluminum nitride ceramic material is used for the support structure, then thermal conductivity is significantly improved, but manufacturing complexity increases
Solution Approach 1:
The aluminum nitride support structure is segmented into multiple plate-like parts that can be manufactured separately and then stacked. This segmentation simplifies the manufacturing of each individual plate while achieving the desired thermal performance in the assembled structure.
Solution Approach 2:
Conductor track structures serve as intermediary elements embedded in the aluminum nitride plates, providing both electrical connection functionality and facilitating the manufacturing process by integrating multiple functions into a single component that can be produced using standard PCB techniques.
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 a compact, efficient operation with high power density and reduced installation space, allowing for high copper fill factor and effective heat management.
Implementation Method 1
the support structure is composed of several support structure parts which are plate-like and stacked on top of each other... using highly thermally conductive materials like aluminum nitride
Implementation Method 2
incorporating cooling channels for efficient heat dissipation
Data Source
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AI summary
The invention relates to an electrical subassembly (1) with a winding, more particularly a machine subassembly, such as a stator, having conductor sections (22) introduced into a receiving body (2) and electrically conducting connecting structures connecting to these conductor sections at one end to produce the winding. An embodiment advantageous for a compact design with an efficient operating mode is obtained by designing at least one connecting structure as a conductor track structure (30) introduced into an electrically insulating substrate structure (5).