Granted Patent B2

US 9,543,809 · App. 14/188,847 · Granted Jan 10, 2017

Abstract

Claims (36)

1. A radial vent composite heat pipe system for cooling and increasing the power density of an electrical machine, said system comprising a plurality of radial vent composite heat pipe assemblies, wherein each heat pipe assembly comprises:

a slot portion disposable within a respective one of a plurality of stator slots of a stator core pack of a stator assembly of an electrical machine; and

a vent portion thermally connected to the slot portion and disposable within a respective one of a plurality of stator vents of the stator assembly, wherein:

the slot portion of each heat pipe assembly is structured and operable to absorb heat from a respective one of a plurality of stator coils of the stator assembly and transfer the absorbed heat to the respective vent portion, and

the vent portion of each heat pipe assembly is structured and operable to reject the transferred heat from the slot portion of the respective heat pipe assembly into a cooling air flowing through the respective stator vent, thereby rapidly transferring heat from the respective stator coil to the cooling air flowing through stator vent.

2. The system of claim 1 , wherein the slot portion of each heat pipe assembly comprises at least one heat pipe having an evaporator end and a condenser end to which the vent portion is thermally connected.

3. The system of claim 2 , wherein the vent portion of each heat pipe assembly comprises a plurality of cooling fins thermally connected to the respective condenser end of the at least one heat pipe.

4. The system of claim 3 , wherein the slot portion of each heat pipe assembly comprises a two-part slot portion comprising a first heat pipe section thermally connected to a second heat pipe section, where:

the first heat pipe section comprises at least one heat pipe; and

the second heat pipe section comprises at least one heat pipe, wherein the condenser end of the first heat pipe section at least one heat pipe is thermally connected to evaporator end of the second heat pipe section at least one heat pipe, and the slot portion is thermally connected to the condenser end of the second heat pipe section at least one heat pipe.

5. The system of claim 4 , wherein the vent portion of each heat pipe assembly comprises a two-part vent portion comprising a first cooling fin array and a second cooling fin array, each thermally connected to the condenser end of the second heat pipe section at least one heat pipe.

6. The system of claim 3 , wherein the slot portion of each heat pipe assembly comprises a heat pipe panel comprising a plurality of the heat pipes and the vent portion is thermally connected to a condenser end of the heat pipe panel.

7. The system of claim 3 , wherein the slot portion of each heat pipe assembly comprises at least one L-shaped heat pipe having a slot leg and a vent leg to which the vent portion is thermally connected.

8. A stator assembly for an electrical machine, said stator assembly comprising:

a plurality of stator core packs assembled together such that a plurality of stator vents are formed between adjacent stator core packs; and

a radial vent composite heat pipe system disposed partially within a plurality of stator slots of each stator core pack and partially within the stator vents, the radial vent composite heat pipe system comprising:

a plurality of radial vent composite heat pipe assemblies, wherein each heat pipe assembly comprises:

a slot portion disposable within a respective one of a plurality of the stator slots; and

a vent portion thermally connected to the slot portion and disposable within a respective one of the stator vents, wherein:

the slot portion of each heat pipe assembly is structured and operable to absorb heat from a respective one of a plurality of stator coils of the stator assembly and transfer the absorbed heat to the respective vent portion, and

the vent portion of each heat pipe assembly is structured and operable to reject the transferred heat from the slot portion of the respective heat pipe assembly into a cooling air flowing through the respective stator vent, thereby rapidly transferring heat from the respective stator coil to the cooling air flowing through stator vent.

9. The stator assembly of claim 8 , wherein the slot portion of each heat pipe assembly comprises at least one heat pipe having an evaporator end and a condenser end to which the vent portion is thermally connected.

10. The stator assembly of claim 9 , wherein the vent portion of each heat pipe assembly comprises a plurality of cooling fins thermally connected to the respective condenser end of the at least one heat pipe.

11. The stator assembly of claim 10 , wherein the slot portion of each heat pipe assembly comprises a two-part slot portion comprising a first heat pipe section thermally connected to a second heat pipe section, where:

the first heat pipe section comprises at least one heat pipe; and

the second heat pipe section comprises at least one heat pipe, wherein the condenser end of the first heat pipe section at least one heat pipe is thermally connected to evaporator end of the second heat pipe section at least one heat pipe, and the slot portion is thermally connected to the condenser end of the second heat pipe section at least one heat pipe.

12. The stator assembly of claim 11 , wherein the vent portion of each heat pipe assembly comprises a two-part vent portion comprising a first cooling fin array and a second cooling fin array, each thermally connected to the condenser end of the second heat pipe section at least one heat pipe.

13. The stator assembly of claim 10 , wherein the slot portion of each heat pipe assembly comprises a heat pipe panel comprising a plurality of the heat pipes and the vent portion is thermally connected to a condenser end of the heat pipe panel.

14. The stator assembly of claim 10 , wherein the slot portion of each heat pipe assembly comprises at least one L-shaped heat pipe having a slot leg and a vent leg to which the vent portion is thermally connected.

15. A method for rapidly transferring heat from stator coils of an electrical machine to a cooling air flowing through stator vents to thereby greatly increasing the power density of the electrical machine, said method comprising:

absorbing heat from a plurality of stator coils of a stator assembly of an electrical machine via a plurality of slot portion of a plurality of radial vent composite heat pipe assemblies disposed within a plurality of stator slots of the stator assembly;

transferring the absorbed heat to vent portions of each heat pipe assembly that are thermally connected to slot portions, the vent portions disposed within the stator vents; and

rejecting the transferred heat, via the vent portions, into a cooling air flowing through the stator vents and the vent portions, thereby rapidly transferring heat from the respective stator coil to the cooling air.

16. The method of claim 15 , wherein absorbing heat from the plurality of stator coils comprises absorbing the heat via an evaporation end of at least one heat pipe of the slot portion of each heat pipe assembly.

17. The method of claim 16 , wherein transferring the absorbed heat to the vent portions of each heat pipe assembly comprises transferring the heat from the evaporator end of each heat pipe of each heat pipe assembly to a condenser end of each heat pipe of each heat pipe assembly.

18. The method of claim 17 , wherein rejecting the transferred heat comprises rejecting the transferred heat into the cooling air flow via a plurality of cooling fins of each vent portion of each heat pipe assembly that are thermally connected to the condenser end of each heat pipe of each heat pipe assembly.

Assignments (17)