Direct Lamination Cooling of Motors For Electric Vehicles

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Current designs for electric motors use a housing that acts as both a structural support and as a method of cooling the stator and rotor. This approach to cooling is not as effective as possible because heat must flow from the rotor and stator through the housing to the cooling media. Because the housing must contain the coolant, it is also larger, heavier, and more expensive than necessary. This project develops a motor that uses a direct lamination cooling (DLC) system, passing coolant directly through the stator and eliminating the need for bulky housing, thereby improving heat transfer. Motor size ... continued below

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Rippel, Wally & Kobayashi, Drayll July 30, 2003.

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Description

Current designs for electric motors use a housing that acts as both a structural support and as a method of cooling the stator and rotor. This approach to cooling is not as effective as possible because heat must flow from the rotor and stator through the housing to the cooling media. Because the housing must contain the coolant, it is also larger, heavier, and more expensive than necessary. This project develops a motor that uses a direct lamination cooling (DLC) system, passing coolant directly through the stator and eliminating the need for bulky housing, thereby improving heat transfer. Motor size could be reduced by up to 30-40%, mass by up to 20-30%, and cost by up to 30%. Phase I demonstrated that reliable lamination-to-lamination seals and reliable stack-to-manifold seals can be achieved using the methods identified. The addition of the selected sealants adds only slightly to the thermal resistance and pressure drop compared with unsealed counterparts. Phase II builds electric motors and inductors using the DLC method, obtain comparative performance data on the effectiveness of the method, and then obtain operational use data on these components through long term testing in a representative environment. The long-term testing will ensure that real world aspects of motor and inductor operation (including vibration, temperature cycling, and the presence of electrical and magnetic fields) do not degrade the seals such that leaking occurs or that the thermal performance degrades.

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  • Report No.: DOE/ER/82940F
  • Grant Number: FG03-00ER82940
  • Office of Scientific & Technical Information Report Number: 834533
  • Archival Resource Key: ark:/67531/metadc783154

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

Office of Scientific and Technical Information (OSTI) is the Department of Energy (DOE) office that collects, preserves, and disseminates DOE-sponsored research and development (R&D) results that are the outcomes of R&D projects or other funded activities at DOE labs and facilities nationwide and grantees at universities and other institutions.

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  • July 30, 2003

Added to The UNT Digital Library

  • Dec. 3, 2015, 9:30 a.m.

Description Last Updated

  • Dec. 9, 2016, 3:48 p.m.

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Rippel, Wally & Kobayashi, Drayll. Direct Lamination Cooling of Motors For Electric Vehicles, text, July 30, 2003; United States. (digital.library.unt.edu/ark:/67531/metadc783154/: accessed October 21, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.