Rotary Electric Machine Terminal Block With Integrated Refrigerant Cooling
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Solution Overview
Problem
Existing rotary electric machines face challenges in cooling the terminal block and refrigerant flow path, leading to increased size and inefficiencies due to separate arrangements that do not allow for effective heat dissipation and interference between metal conductors and refrigerant flow paths.
Innovation Solution
An integrated structure is developed where electric power wires and a refrigerant flow path are positioned in proximity from different directions, forming a compact and efficient cooling system with a molded structure that includes an insulating resin and higher thermal conductivity fillers, allowing for effective heat exchange and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the terminal block and refrigerant flow path are arranged separately and adjacent to each other, then the cooling performance is improved, but the overall size is increased
Solution Approach 1:
The patent integrates the refrigerant flow path directly into the terminal block structure, merging two previously separate components. The terminal block serves dual functions as both an electrical connection component and a refrigerant distribution manifold, with refrigerant flow paths formed within the terminal block body itself. This integration eliminates the need for separate adjacent arrangements while maintaining effective cooling of the bus bar through direct thermal contact with the refrigerant flow path.
2Temperature
If the electric power wires are positioned in proximity to the refrigerant flow path from different directions, then the cooling performance is improved, but the structural complexity is increased
Solution Approach 1:
The patent combines multiple refrigerant flow paths within a single integrated terminal block structure, allowing electric power wires to be cooled from multiple directions without requiring separate external cooling components. The terminal block internally routes refrigerant flow paths to contact bus bar surfaces from different directions, achieving multi-directional cooling through a unified structure rather than separate cooling systems.
Solution Approach 2:
The terminal block serves multiple functions simultaneously: electrical connection, refrigerant distribution, and multi-directional heat dissipation. By integrating these functions into a single component, the patent achieves complex cooling patterns without proportionally increasing structural complexity, as the same structural elements perform multiple roles.
3Weight of stationary object
If the transverse cross-sectional area of the electric power wire is reduced, then the weight is reduced, but the heat dissipation capability is worsened
Solution Approach 1:
The patent compensates for reduced wire cross-sectional area by extending the cooling interaction in the spatial dimension. The integrated terminal block creates extended refrigerant flow paths that wrap around and contact the bus bar from multiple directions and positions, increasing the effective heat exchange surface area and duration without requiring larger wire cross-sections. This multi-point, multi-directional cooling approach allows thinner wires to achieve adequate heat dissipation.
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 integrated structure provides excellent cooling performance, reduces the size and weight of the electric power wires, and prevents interference, maintaining stable positional relationships despite impacts, while ensuring insulating properties.
Implementation Method 1
the two electric power wires are in proximity to a single cooling flow path from different directions. Thus, it is possible to effectively cool the two electric power wires with a single cooling flow path
Implementation Method 2
cool the rotary electric machine by circulation of a refrigerant
Implementation Method 3
a molded structure that includes an insulating resin and higher thermal conductivity fillers, allowing for effective heat exchange
Data Source
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AI summary
One refrigerant flow path 110, through which a refrigerant flows, and two electric power wires 70, 80, through each of which a current to energize a rotary electric machine 2 flows, are provided. The two electric power wires 70, 80 are arranged inside an integrated structure portion 50 in a manner to be in proximity to the refrigerant flow path 110 from different directions.