Aircraft Motor Windings With Variable-Section Boiling Cooling

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Solution Overview

Problem

Traditional electric motors for aircraft applications face limitations in power density and weight due to thermal management issues, as conventional cooling methods like natural convection and liquid cooling add volume and weight, restricting heat dissipation and electrical current capacity.

Innovation Solution

The integration of two-phase cooling channels within the motor windings, with a decreasing cross-sectional area from inlet to outlet, allows for efficient heat transfer and phase change of the cooling fluid, enhancing thermal management while maintaining a compact and lightweight design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional cooling methods (natural convection or liquid cooling) are used, then heat dissipation is achieved, but volume and weight increase due to the addition of cooling jackets

Engineering Contradiction:

Improveheat dissipationVSAvoidmotor weight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The cooling channels are merged with the motor windings by being integrally formed within them. This combines the electrical winding structure with the thermal management function, eliminating the need for separate cooling jackets and reducing overall motor weight while maintaining effective heat dissipation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling channels are nested within the motor windings, placing the cooling function inside the existing winding structure. This nested arrangement allows the cooling system to occupy space already allocated for windings, avoiding additional volume and weight from external cooling components

Inventive Principle:

Principle #7Nested doll (Nesting)

2Temperature

If conventional cooling methods (natural convection or liquid cooling) are used, then heat dissipation is achieved, but volume increases due to the addition of cooling jackets

Engineering Contradiction:

Improveheat dissipationVSAvoidmotor volume

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The cooling channels are merged with the motor windings by being integrally formed within them. This combines the electrical winding structure with the thermal management function, eliminating the need for separate cooling jackets and reducing overall motor volume while maintaining effective heat dissipation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If cooling channels with constant cross-sectional area are used, then manufacturing is simplified, but heat transfer efficiency decreases due to inadequate accommodation of phase change

Engineering Contradiction:

Improvecooling channel manufacturingVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The cooling channel cross-sectional area varies along its length, with the inlet having a smaller area and the outlet having a larger area. This local variation in geometry is specifically designed to accommodate the phase change of the cooling fluid, improving heat transfer efficiency where needed without complicating the overall manufacturing process

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cross-sectional area parameter of the cooling channel is changed along its length to optimize thermal performance. By increasing the area from inlet to outlet, the channel accommodates the expanding cooling fluid during phase change, enhancing heat transfer efficiency while maintaining a manufacturable design

Inventive Principle:

Principle #35Parameter changes

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 solution improves thermal efficiency, power density, and reduces weight by effectively managing heat generation within the motor windings, enabling higher electrical current capacity without increasing the motor's volume or weight.

Implementation Method 1

an inlet to receive a two-phase cooling fluid and an outlet configured to discharge the two-phase cooling fluid

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

cooling channels arranged to provide cooling to the plurality of windings

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

cooling channels arranged to provide cooling to the plurality of windings

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS11990825B2Aircraft electric motor

Publication Date: 2024.05.21 HAMILTON SUNDSTRAND CORP

AI summary

Aircraft electric motors are described. The aircraft electric motors includes a motor unit having a rotor and a stator, wherein the stator includes a plurality of windings and cooling channels arranged to provide cooling to the plurality of windings, a drive unit configured to drive operation of the motor unit, and a cooling system. The cooling system includes at least one cooling channel integrally formed within at least one winding, wherein the at least one cooling channel comprises an inlet to receive a two-phase cooling fluid and an outlet configured to discharge the two-phase cooling fluid, wherein a cross-sectional area of the at least one cooling channel at the inlet is less than a cross-sectional area of the at least one cooling channel at the outlet.