Hamilton Sundstrand Corporation

Raytheon Company

B/e Aerospace, Inc.

Rockwell Collins, Inc.

Hamilton Sundstrand Space Systems International, Inc.

Kimberly Rae Saviers

Jagadeesh Kumar Tangudu

Abbas A Alahyari

Joseph E Turney

Ram Ranjan

Andrzej Ernest Kuczek

Ross Keith Wilcoxon

Kathryn L Kirsch

Aritra Sur

Matthew Robert Pearson

Zaffir A Chaudhry

Wenping Zhao

Brian St Rock

Jonathan Rheaume

Robert H Dold

John H Whiton

Neal R Herring

Joseph C Rampone

Huan Zhang

Joshua M Norman

Jeffrey Ewanchuk

Shane Haydt

Haley Steffen

A header for an electric machine that include a stator core and one or more windings that include coolant passages formed therein. The header includes an inlet to receive a coolant, an outlet though which the coolant exits the header, an inlet plenum fluidly connected to the inlet, and an outlet plenum fluidly separated from the inlet plenum and fluidly connected to the outlet. The inlet and outlet plenums each have a varying cross section that varies from a top of the header as compared to a bottom of the header.

Header guiding fluid flow to and from cooling channels in a high density motor

In accordance with at least one aspect of this disclosure, a system includes a liquid-gas separator. The liquid-gas separator includes: a substantially planar body configured to be seated in a fluid flow to separate a flow of liquid from the fluid flow, one or more apertures disposed in the body configured collect the flow of liquid, and one or more diverters integrally formed on or in the body configured divert the flow of liquid towards the one or more apertures. In certain embodiments, the planar body can be additively manufactured.

Air-water separator for condensing heat exchanger

Stators for aircraft electric motors include a cantilever structure having a supported end and an unsupported end, wherein the cantilever structure includes an inlet support manifold and an outlet support manifold arranged at the supported end and a plurality of cooling plates extending from the inlet support manifold and the outlet support manifold to the unsupported end. A plurality of coils are arranged between and in thermal contact with the cooling plates and a core passes through the plurality of coils and the plurality of cooling plates. Each cooling plate defines a cooling channel that fluidly couples the inlet support manifold and the outlet support manifold, and the coils and the core are structurally supported by the plurality of cooling plates in a cantilevered manner at the supported end.

Electric machine having multi-function cooling channels

A heat sink with a primary flow volume, an inlet, an outlet, a bottom plate, a top plate, distribution, heat transfer and collector sections, and flow paths between pillars. The inlet cross-section defines the primary flow volume cross-section and the length of the primary flow volume extends into the heat sink at a right angle to the inlet cross-section. The distribution section is proximate to the flow inlet and has distribution pillars extending from the bottom or top plate. The heat transfer section is proximate to the distribution section and has heat transfer pillars extending from the bottom or top plate. The collector section is proximate to the heat transfer section and has collector pillars extending from the bottom or top plate. The distribution cross-section is greater than the heat transfer cross-section which is smaller than the collector cross-section. The outlet and the flow paths extend outside of the primary flow volume.

Varying topology heat sinks

A stator for an electrical machine can include a plurality of windings, each forming a coil and end connections. The stator can include a first potting material having a first viscosity and a first thermal conductivity. The first potting material can be disposed on each coil and fills gaps between each coil. The stator can include a second potting material different from the first potting material and having a second viscosity and a second thermal conductivity. The second viscosity can be higher than the first viscosity and the second thermal conductivity is higher than the first thermal conductivity. The second potting material can be disposed on each of the end connections to provide increased thermal conductivity from the end connections.

Multiple potting material structures

A system for cooling a power component includes a first metal layer. A cooling layer having a first surface is in contact with a surface of the first metal layer. A second metal layer is included having a surface in contact with a second surface of the cooling layer opposite the first metal layer. The cooling layer is of a material different from that of the first metal layer and that of the second metal layer. A plurality of cooling features are embedded in the material of the cooling layer. The cooling channels are spaced apart from both the first metal layer and the second metal layer by the material of the cooling layer. An electrically conductive path connects the first metal plate to the second metal plate.

Cooling in conductors for chips

A heat sink with a primary flow volume, an inlet, an outlet, a bottom plate, a top plate, distribution, heat transfer and collector sections, and flow paths between pillars. The inlet cross-section defines the primary flow volume cross-section and the length of the primary flow volume extends into the heat sink at a right angle to the inlet cross-section. The distribution section is proximate to the flow inlet and has distribution pillars extending from the bottom or top plate. The heat transfer section is proximate to the distribution section and has heat transfer pillars extending from the bottom or top plate. The collector section is proximate to the heat transfer section and has collector pillars extending from the bottom or top plate. The distribution cross-section is greater than the heat transfer cross-section which is smaller than the collector cross-section. The flow paths extend outside of the primary flow volume.

Aircraft electric motors are described. The aircraft electric motors include 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 an oscillating heat pipe containing a first working fluid, wherein the oscillating heat pipe is arranged to pick up heat from at least one winding, the oscillating heat pipe having an evaporator section arranged in thermal contact with the at least one winding and a condenser section arranged away from the evaporator section and a heat pickup portion arranged to receive a second working fluid to remove heat from the condenser section of the oscillating heat pipe.

Aircraft electric motor having a stator heat pipe cooling scheme

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.

Aircraft electric motor

A heat transfer system (e.g., a heat pump) can include at least a first fin array and at least a first pump disposed in fluid communication with the first fin array and configured to cause a first fluid to flow through the first fin array. The system can include at least a first heat transfer layer attached to and/or in thermal communication with the first fin array. The first heat transfer layer can define a second fluid flow path therein for a second fluid to flow fluidly isolated from the first fluid. The first heat transfer layer and the first fin array can be configured to cause heat transfer between the first fluid and the second fluid.

Heat transfer systems

A cold plate apparatus is disclosed. A cold plate includes a first set of sinusoidal conduits and a second set of sinusoidal conduits formed therein. The first set of sinusoidal conduits is arranged in a first direction, and the second set of sinusoidal conduits is arranged in a second direction. Crests of the first set of sinusoidal conduits overlap troughs of the second set of sinusoidal conduits. Crests of the second set of sinusoidal conduits overlap troughs of the first set of sinusoidal conduits. A first set of header plates is fluidically coupled to the first set of sinusoidal conduits, and a second set of header plates is fluidically coupled to the second set of sinusoidal conduits.

Textile weave redundant loop cold plate design

Aircraft electric motors include a motor unit having a rotor and a stator. The stator includes a plurality of windings and cooling channels arranged to provide cooling thereto. A drive unit is configured to drive operation of the motor unit. A cooling system includes a working fluid arranged within a cooling fluid flow path, wherein the cooling fluid flow path includes a liquid cooling path configured to direct flow of the working fluid through, at least, the cooling channels of the motor unit and a vapor cooling path configured to direct flow of the working fluid through the drive unit and a separator arranged upstream of each of the liquid cooling path and the vapor cooling path and configured to direct a liquid portion of the working fluid into the liquid cooling path and configured to direct a vapor portion of the working fluid into the vapor cooling path.

Aircraft electric motor with integrated cooling system

A stator of an electric motor includes a stator core including a rim and a plurality of stator teeth extending from the rim. The plurality of stator teeth define a plurality of tooth gaps between circumferentially adjacent stator teeth. A plurality of stator windings are wrapped along the plurality of stator teeth. The plurality of stator windings include a plurality of core segments extending along the plurality of tooth gaps, and a plurality of end turn segments connecting adjacent core segments. A plurality of non-electrically conductive cooling channels are located in the stator core. The plurality of cooling channels are configured to direct a cooling fluid flow therethrough to cool the plurality of stator windings.

Electric motor with cooling channels

Aircraft electric motors are described. The aircraft electric motors include 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 having at least one directional feature forming a portion of at least one cooling channel, the at least one directional feature configured to prevent backflow of a cooling fluid that passes through the at least one cooling channel.

Aircraft electric motors are described. The aircraft electric motors include a cooling system comprising an annular heat exchanger, a motor housing arranged radially inward from the heat exchanger, the motor housing defining a rotor-stator cavity and a gear assembly cavity, a rotor sleeve arranged within the rotor-stator cavity, a gear assembly arranged within the gear assembly cavity, a first shaft operably coupled to the rotor sleeve and configured to be rotationally driven by the rotor sleeve to drive rotation of a portion of the gear assembly, and a second shaft operably coupled to the gear assembly and configured to be rotationally driven by the gear assembly.

Growing community of inventors

Glastonbury, CT, United States of America

Kimberly Rae Saviers