Systems and method for embedded direct winding cooling for electric machines
A method includes fabricating a core, wherein the core comprises a chemically soluble first polymer, forming a body around the core, wherein the body comprises a second polymer, and etching away the core to reveal a cooling channel extending through the body.
1. A method, comprising:
fabricating a core, wherein the core comprises a chemically soluble first polymer;
forming a cooling slot liner for an electric machine around the core, wherein the cooling slot liner comprises a second polymer; and
etching away the core to reveal a cooling channel extending through the cooling slot liner, wherein a cross section of the cooling channel is fully enclosed by the cooling slot liner.
2. The method of claim 1 , comprising installing the body within an electric machine, adjacent a conductor, and flowing a coolant through the cooling channel.
3. The method of claim 2 , wherein installing the body within an electric machine comprises inserting the body into a stator slot of the electric machine.
4. The method of claim 3 , comprising:
installing one or more conductors within the stator slot of the electric machine, and filling the stator slot with resin.
5. The method of claim 2 , wherein installing the body within the electric machine comprises coupling the body to an end of a stator of the electric machine.
6. The method of claim 5 , wherein the conductor is an end winding, an end winding ring, or a combination thereof.
7. The method of claim 1 , wherein the core comprises a water-soluble polymer.
8. The method of claim 7 , wherein the core comprises polyvinyl alcohol (PVA).
9. A cooling slot liner for an electric machine, comprising:
a core comprising a chemically-soluble first polymer; and
a cooling slot liner body formed about the core, wherein the cooling slot liner body comprises a second polymer;
wherein flowing an etching fluid through the cooling slot liner body etches away the core to reveal a cooling channel, wherein a cross section of the cooling channel is fully enclosed by the cooling slot liner body, wherein the cooling slot liner is configured to be installed within a stator slot of an electrical machine, adjacent one or more conductors, and wherein flowing a coolant through the cooling channel draws heat from the one or more conductors.
10. The cooling slot liner of claim 9 , wherein the first polymer is water-soluble.
11. The cooling slot liner of claim 10 , wherein the first polymer comprises polyvinyl alcohol (PVA).
12. The cooling slot liner of claim 9 , comprising:
an entry fluidly coupled to the cooling channel; and
an exit fluidly coupled to the cooling channel.
13. The cooling slot liner of claim 9 , comprising a plurality of cooling channels extending through the cooling slot liner body.
14. The cooling slot liner of claim 9 , wherein the core defines a central passage through which the etching fluid flows.