Thermal Conductor with Dielectric Coating for Electric Machine Heat Dissipation
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Solution Overview
Problem
Existing electric machines face challenges in efficiently dissipating heat generated at stator end-turns due to low thermal conductivity of known thermal conductors, which limits power density and requires complex cooling systems.
Innovation Solution
A thermal conductor comprising a substrate with a thermally conductive, dielectric coating, including a transition layer and a thermally conductive layer, is positioned between the stator end-turns and the housing, facilitating effective heat transfer and dissipation using materials with higher thermal conductivity than traditional polyimide-based conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyimide-based thermal conductors are used, then electrical insulation is provided, but thermal conductivity is low which limits heat dissipation
Solution Approach 1:
The patent applies composite materials by combining a polyimide substrate with a thermally conductive dielectric coating layer. This composite structure integrates the electrical insulation properties of polyimide with the enhanced thermal conductivity of the coating material (such as aluminum oxide, magnesium oxide, or boron nitride), thereby resolving the contradiction between electrical insulation and heat dissipation capability.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the thermal conductor by adding a dielectric coating layer with high thermal conductivity. This parameter change allows the thermal conductor to maintain electrical insulation while significantly improving heat dissipation capability, directly addressing the technical contradiction.
2Temperature
If spray cooling systems are used, then heat dissipation is improved, but system complexity increases due to required liquid supply components
Solution Approach 1:
The patent extracts the cooling function from a complex external spray cooling system and integrates it directly into the thermal conductor component itself. By incorporating the thermally conductive dielectric coating on the substrate, the heat dissipation function is built into the existing thermal conductor, eliminating the need for separate liquid supply systems and reducing overall system complexity.
Solution Approach 2:
The thermal conductor with dielectric coating serves itself by providing both electrical insulation and heat dissipation functions through its own structure. The high thermal conductivity of the coating material enables the thermal conductor to dissipate heat inherently without requiring external cooling systems, making the system self-sufficient and simpler.
3Power
If higher power density is achieved, then power output increases, but heat generation increases requiring more complex cooling
Solution Approach 1:
The patent changes the thermal conductivity parameter of the thermal conductor by incorporating a thermally conductive dielectric coating. This parameter enhancement allows the system to handle higher heat generation from increased power density without requiring more complex cooling systems, as the improved thermal conductor can dissipate the additional heat more effectively.
Solution Approach 2:
By using composite materials (polyimide substrate with thermally conductive dielectric coating), the patent creates a thermal conductor that can manage the heat generated by high power density applications. The composite structure provides both the electrical insulation needed for high power operation and the thermal conductivity required to dissipate the resulting heat, avoiding the need for complex cooling systems.
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 thermal conductor enhances heat dissipation from electric machines, increasing power density and reducing the need for complex cooling systems, allowing for higher power output or more compact designs.
Implementation Method 1
The thermally conductive coating includes a thermally conductive, dielectric material configured to transfer heat from the plurality of end-turns to the substrate
Data Source
AI summary
An electric machine includes a housing, a stator core positioned within the housing, a wire wound about the stator core to form a plurality of end-turns that extend from an end of the stator core, and a thermal conductor positioned between the plurality of end-turns and the housing. The thermal conductor includes a substrate and a thermally conductive coating formed on a surface of the substrate. The thermally conductive coating includes a thermally conductive, dielectric material configured to transfer heat from the plurality of end-turns to the substrate.