111111
`
`1111111111111111111111111111111111111111111111111111111111111
`US007683509B2
`US007683509B2
`
`(12) United States Patent
`(12) United States Patent
`Neal
`Neal
`
`(10) Patent No.:
`(10) Patent No.:
`(45) Date of Patent:
`(45) Date of Patent:
`
`US 7,683.509 B2
`US 7,683,509 B2
`Mar. 23,2010
`Mar. 23, 2010
`
`(54) ELECTROMAGNETIC DEVICE WITH OPEN,
`(54) ELECTROMAGNETIC DEVICE WITH OPEN,
`NON-LINEAR HEAT TRANSFER SYSTEM
`NON-LINEAR HEAT TRANSFER SYSTEM
`
`(75) Inventor: Griffith D. Neal, Alameda, CA (US)
`(75)
`Inventor: Griffith D. Neal, Alameda, CA (US)
`
`6,903,471 B2 * 6/2005 Arimitsu et al. ............... 310/59
`6,903,471 B2 * 6/2005 Arimitsu et al. ............... 310/59
`6,986,647 B2 *
`6,986,647 B2 *
`1/2006 Jones et al. .......
`... 417/357
`112006 Jones et al. ................. 417/357
`7,186,093 B2 * 3/2007 Goshi .......................... 417/53
`7,186,093 B2 * 3/2007 Goshi ............
`... 417/53
`7,196,439 B2 * 3/2007 Pierret et al. .................. 310/58
`7,196,439 B2 * 3/2007 Pierret et al. .................. 310/58
`
`(73) Assignee: Encap Technologies Inc., Alameda, CA
`(73) Assignee: Encap Technologies Inc., Alameda, CA
`(US)
`
`-- - *--> -
`
`y
`
`ays.
`
`ABSTRACT
`ABSTRACT
`
`-
`-
`* cited by examiner
`eXainliner
`C11e
`Primary Examiner-Michael C Zarroli
`Primary Examiner—Michael C Zarroli
`-
`-
`-
`-
`* * * *
`sk
`Subject to any disclaimer, the term of this
`( *) Notice:
`(*) Notice: º to . º: º º: (74) Attorney, Agent, or Firm—Brinks Hofer Gilson & Lione;
`(74 ) Attorney, Agent, or Firm-Brinks Hofer Gilson & Lione;
`tºº seersºn,
`patent is extended or adjusted under 35
`Steven P. Shurtz
`U.S.c. 154(b) by 661 days.
`(57)
`57
`(21) Appl. No.: 11/489,914
`(57)
`(21) Appl. No.: 11/489,914
`(22) Filed:
`Jul.19, 2006
`Electromagnetic components are provided with a heat
`Electromagnetic components are provided with a heat
`(22) Filed:
`Jui. 19, 2006
`exchange mechanism. For example, a fluid-cooled electro
`exchange mechanism. For example, a fluid-cooled electro(cid:173)
`magnetic field-functioning device, such as a motor, generator,
`Prior Publication Data
`Prior Publication Data
`magnetic field-functioning device, such as a motor, generator,
`transformer, solenoid or relay, comprises one or more elec(cid:173)
`transformer solenoid or relay, comprises one or more elec
`|US 2008/0017354 A1
`Jan. 24, 2008
`US 200S/0017354 Al
`Jan. 24,200S
`trical conductors. A monolithic body of phase change mate
`trical conductors. A monolithic body of phase change mate(cid:173)
`rial substantially encapsulates the conductors or an inductor.
`(51) Int. Cl.
`rial substantially encapsulates the conductors or an inductor.
`(51)
`Int. CI.
`At least one liquid-tight coolant channel is also substantially
`At least one liquid-tight coolant channel is also substantially
`(2006.01)
`H02K II/0?)
`(2006.01)
`H02K 11/00
`encapsulated within the body ºf phase change material. The
`(52) U.S. Cl. ........................... 310,54.31058, 180651
`encapsulated within the body of phase change material. The
`(52) U.S. CI. ........................... 310/54; 31O/5S; IS0/65.1
`coolant channel may be part of a heat pipe or cold plate. The
`coolant channel may be part of a heat pipe or cold plate. The
`e
`e
`e
`(5S) Field of Classification Search ................... 310/54,
`lant ch
`1
`|b
`de b
`ldi
`duit into th
`(58) Field of Classification Search ................... 310/54,
`coolant channel may be made by molding a conduit into the
`31052,43,58-59, 64; 18065.1 ...". "...".
`310/52,43, 5S-59, 64; IS0/65.1
`body, using a "lost wax" molding process, or injecting gas
`-
`. -
`3 * ~ *
`-
`ody, using a “lost wax” molding process, or injecting gas
`See application file for complete search history.
`See application file for complete search history.
`into the molten phase change material while it is in the mold.
`into the molten phase change material while it is in the mold.
`References Cited
`The coolant channel may also be formed at the juncture
`The coolant channel may also be formed at the juncture
`References Cited
`between the body and a cover over the body.
`U.S. PATENT DOCUMENTS
`between the body and a cover over the body.
`U.S. PATENT DOCUMENTS
`5,072,145 A * 1211991 Davis et al .................... 310/54
`5,072,145 A * 12/1991 Davis et al. ................... 310/54
`
`16 Claims, 14 Drawing Sheets
`16 Claims, 14 Drawing Sheets
`
`(65)
`(65)
`
`(56)
`(56)
`
`
`
`289
`
`283
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0001
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23, 2010
`Mar. 23,2010
`
`Sheet 1 of 14
`Sheet 1 of 14
`
`US 7,683,509 B2
`US 7,683.509 B2
`
`\ \
`
`-
`
`
`
`
`
`18W 8018 d. | 9 | -!
`
`\
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0002
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23, 2010
`Mar. 23, 2010
`
`Sheet 2 of 14
`Sheet 2 of 14
`
`US 7,683,509 B2
`US 7,683.509 B2
`
`
`
`\
`
`Q--'
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0003
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23, 2010
`Mar. 23,2010
`
`Sheet 3 of 14
`Sheet 3 of 14
`
`US 7,683,509 B2
`US 7,683.509 B2
`
`FIG.4
`
`
`
`
`
`
`
`16 -
`
`18
`
`30 -
`
`17
`
`48
`
`26
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0004
`
`

`

`u.s. Patent
`U.S. Patent
`
`
`
`
`
`Mar. 23,2010
`Mar. 23, 2010
`
`Sheet 4 of 14
`Sheet 4 of 14
`
`US 7,683,509 B2
`
`tO~~
`
`• <..9 -~~~~~~~~~
`
`o
`C\I
`
`,
`I ,
`L()I .
`(!) -
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0005
`
`

`

`u.s. Patent
`U.S. Patent
`
`
`
`Mar. 23, 2010
`Mar. 23, 2010
`
`Sheet 5 of 14
`Sheet 5 of 14
`
`US 7,683.509 B2
`US 7,683,509 B2
`
`co
`(\J
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0006
`
`

`

`u.s. Patent
`
`Mar. 23,2010
`
`Sheet 6 of 14
`
`US 7,683,509 B2
`
`•
`
`<..9 -
`lJ.-
`
`CX)
`.
`(9
`J.-
`
`-l
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0007
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23, 2010
`Mar. 23,2010
`
`Sheet 7 of 14
`Sheet 7 of 14
`
`US 7,683,509 B2
`US 7,683.509 B2
`
`
`
`..
`
`o
`<..9 -
`LL
`
`c 1
`
`..
`
`.. :
`j
`,
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0008
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23, 2010
`Mar. 23, 2010
`
`Sheet 8 of 14
`Sheet 8 of 14
`
`US 7,683.509 B2
`US 7,683,509 B2
`
`
`
`FIG. 11
`
`f I
`
`W
`I
`
`'i I .
`
`&
`1102
`
`•
`
`! 1124 ~ '.0W;
`I
`!11~ .... ~ •.. i.
`I
`" " "' ...
`L./'1!!·'
`I
`
`1112
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0009
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23, 2010
`Mar. 23,2010
`
`Sheet 9 of 14
`Sheet 9 of 14
`
`US 7,683,509 B2
`US 7,683.509 B2
`
`
`
`|||||||||||||
`
`.
`<.9 -
`
`•
`
`(9 -LL
`
`to
`Q)
`C\I
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0010
`
`

`

`11. = \C = N
`
`US 7,683.509 B2
`
`W
`QO
`0..,
`-....l
`rJl
`d
`
`....
`0 ....
`0
`....
`.....
`rFJ =- ('D
`
`Sheet 10 of 14
`
`.j;o.
`
`('D
`
`0
`
`~
`
`~ :-:
`~
`
`(.H
`N
`
`~ = ~
`
`~
`~
`~
`•
`7Jl
`~
`
`U.S. Patent
`
`Mar. 23, 2010
`
`0 ....
`
`N
`
`
`
`||||||||
`
`l
`I W((T((((( (l\ \
`
`\
`() I
`
`2.2
`
`289
`
`F1G.14
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0011
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23,2010
`Mar. 23, 2010
`
`Sheet 11 of 14
`Sheet 11 of 14
`
`US 7,683.509 B2
`US 7,683,509 B2
`
`N
`
`|------
`NN
`[…]
`
`802
`
`!pyy
`
`((((
`¿???????)(((
`
`% Z %
`
`o
`ro
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0012
`
`

`

`u.s. Patent
`
`Mar. 23, 2010
`
`Sheet 12 of 14
`
`US 7,683,509 B2
`
`FIG. 17
`
`362
`
`350
`
`'\..1
`,,"r /
`
`/
`
`/
`
`/
`
`/
`
`/
`
`/
`
`/
`
`"
`
`~ ~ /
`/ /1"
`~
`~ .-358
`~~
`~
`3--52 ~
`. ~Nk./357
`--~""-~
`:'"
`"
`:,
`,',
`~ r-
`-- -,
`"
`--: "'''' '""-
`-,,, -
`,,-
`364/~')t~,~ ~ ~~~~ 364
`-c
`360
`
`.~ "
`
`--
`
`r\..
`f.;..
`~
`
`t\.
`
`-
`
`-;
`
`- ,
`
`oO
`
`-
`
`,/.
`7.
`
`-
`
`.
`
`-
`
`.- . ," .
`. ~.~
`
`.,'
`- "'
`
`- =
`-.~
`
`~
`
`-
`
`. _ ,_
`
`-
`
`'
`
`_ .. ,"
`
`.
`
`~
`~
`.t) 354
`t\.
`\
`
`(
`)
`
`:;:'"
`
`or';;
`
`~,,-,~ -
`..
`
`\
`
`..
`
`-
`
`,
`
`' .
`
`-,
`
`r
`
`"
`
`;
`
`.. ~-
`
`"
`
`"
`
`>
`
`•
`
`356
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0013
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 23, 2010
`Mar. 23, 2010
`
`Sheet 13 of 14
`Sheet 13 of 14
`
`US 7,683.509 B2
`US 7,683,509 B2
`
`FIG.18
`
`No.<<<<<<SS),
`XXX:X:X:X:X:X:X:X:X:X:XX
`
`424 ,--",,-"i.I
`
`FIG. 19
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`19
`--t~OO
`'20 ~
`
`402
`
`412
`
`406
`
`']'¥.:I.-"Ill I a
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0014
`
`

`

`U.S. Patent
`Mar. 23, 2010
`Sheet 14 of 14
`Sheet 14 of 14
`Mar. 23,2010
`u.s. Patent
`F \ G. 20 41.-:\-0 __ - - -
`
`468
`
`
`
`us 7 ~683~509 B2
`US 7,683.509 B2
`
`~50
`452 f
`
`458
`
`33
`
`§ § §ll N § §§ N §
`
`- ; . , - / ,"
`
`F \ G. 2 ,. ~ ____ 4.--72.--:-::::::::::-
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0015
`
`

`

`US 7,683,509 B2
`US 7,683,509 B2
`
`1
`1
`ELECTROMAGNETIC DEVICE WITH OPEN,
`ELECTROMAGNETIC DEVICE WITH OPEN,
`NON-LINEAR HEAT TRANSFER SYSTEM
`NON-LINEAR HEAT TRANSFER SYSTEM
`
`FIELD OF THE INVENTION
`FIELD OF THE INVENTION
`
`The present invention relates generally to electromagnetic
`The present invention relates generally to electromagnetic
`devices that include heat exchange mechanisms. It relates
`devices that include heat exchange mechanisms. It relates
`particularly to motors, generators, transformers, relays and
`particularly to motors, generators, transformers, relays and
`solenoids that are cooled by a fluid coolant. The devices can
`solenoids that are cooled by a fluid coolant. The devices can
`be used in various electronic products, such as a motor for
`be used in various electronic products, such as a motor for
`hard disc drive or other consumer electronic device, a pump
`hard disc drive or other consumer electronic device, a pump
`motor, a motor/generator used in a hybrid electric vehicle, a
`motor, a motor/generator used in a hybrid electric vehicle, a
`motor used in an air blower and a solenoid used in a fuel
`motor used in an air blower and a solenoid used in a fuel
`injector or liquid flow valve.
`injector or liquid flow valve.
`In addition to the present application, Applicant has filed
`In addition to the present application, Applicant has filed
`four other applications with similar disclosures but different
`four other applications with similar disclosures but different
`claims. Those applications are as follows: application Ser.
`claims. Those applications are as follows: application Ser.
`No. 11/485,822; application Ser. No. 11/489,911; application
`No. 111485,822; application Ser. No. 111489,911; application
`Ser. No. 11/489,912; and application Ser. No. 11/489,913.
`Ser. No. 111489,912; and application Ser. No. 111489,913.
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`2
`2
`liquids in particular, typically have a high enough heat capac
`liquids in particular, typically have a high enough heat capac(cid:173)
`ity that they can be used to carry away heat. For example, a
`ity that they can be used to carry away heat. For example, a
`water pump driven by a motor uses the water to cool the
`water pump driven by a motor uses the water to cool the
`pump. The problem with liquids, however, is getting them in
`pump. The problem with liquids, however, is getting them in
`contact with hot motor surfaces without damaging the motor,
`contact with hot motor surfaces without damaging the motor,
`and then collecting them to carry them away. Thus, a need
`and then collecting them to carry them away. Thus, a need
`exists for an improved motor that includes an effective and
`exists for an improved motor that includes an effective and
`practical way of using a liquid to carry heat away from the
`practical way of using a liquid to carry heat away from the
`motor. Also, a need exits for improved methods of cooling
`motor. Also, a need exits for improved methods of cooling
`other electromagnetic components.
`10 other electromagnetic components.
`10
`Also, there are times when the heat generated by operation
`Also, there are times when the heat generated by operation
`of the electrical device, such as a motor, could be put to a
`of the electrical device, such as a motor, could be put to a
`beneficial use if there were a way to confine a fluid used in a
`beneficial use if there were a way to confine a fluid used in a
`heat transfer relationship with the device so that it could be
`heat transfer relationship with the device so that it could be
`directed to a point of desired use. Thus, if liquids or gasses
`15 directed to a point of desired use. Thus, if liquids or gasses
`15
`could be channeled in such a way that they picked up heat
`could be channeled in such a way that they picked up heat
`from an electromagnetic device without damaging the device,
`from an electromagnetic device without damaging the device,
`and then carried that heat to a place where the heat was
`and then carried that heat to a place where the heat was
`desired, that would be a great benefit.
`desired, that would be a great benefit.
`One difficulty encountered in the design of electrical com
`One difficulty encountered in the design of electrical com(cid:173)
`ponents is that various components need to withstand expo
`ponents is that various components need to withstand expo(cid:173)
`sure to solvents and particulates. The environmental agents
`sure to solvents and particulates. The environmental agents
`can corrode the conductors or inductors in the component. In
`can corrode the conductors or inductors in the component. In
`pumps used for movement of corrosive agents, this can be a
`pumps used for movement of corrosive agents, this can be a
`particular problem. In hybrid electric vehicles where the
`25
`25 particular problem. In hybrid electric vehicles where the
`motor or generatorresides inside of the transmission housing,
`motor or generator resides inside of the transmission housing,
`stray metallic debris generated from the transmission gears
`stray metallic debris generated from the transmission gears
`may be thrown into the windings, damaging them to the point
`may be thrown into the windings, damaging them to the point
`that the device no longer works.
`that the device no longer works.
`
`20
`20
`
`The present invention utilizes aspects of Applicant’s earlier
`The present invention utilizes aspects of Applicant's earlier
`inventions, some of which are repeated herein. U.S. Pat. Nos.
`inventions, some of which are repeated herein. U.S. Pat. Nos.
`6,362,554, 6,753,682 and 6,911,166, which are hereby incor
`6,362,554; 6,753,682 and 6,911,166, which are hereby incor(cid:173)
`porated by reference, further disclose some of these concepts.
`porated by reference, further disclose some of these concepts.
`An example of a conventional motor 1 is shown in FIG. 1.
`An example of a conventional motor 1 is shown in FIG. 1.
`The motor 1 includes a base 2 which is usually made from die
`The motor 1 includes a base 2 which is usually made from die
`cast aluminum, a stator 4, a shaft 6, bearings 7 and a disc
`cast aluminum, a stator 4, a shaft 6, bearings 7 and a disc
`support member 8, also referred to as a hub. A magnet 3 and
`support member 8, also referred to as a hub. A magnet 3 and 30
`30
`flux return ring 5 are attached to the disc support member 8.
`flux return ring 5 are attached to the disc support member 8.
`The stator 4 is separated from the base 2 using an insulator
`The stator 4 is separated from the base 2 using an insulator
`(not shown) and attached to the base 2 using a glue. Distinct
`(not shown) and attached to the base 2 using a glue. Distinct
`structures are formed in the base 2 and the disc support
`structures are formed in the base 2 and the disc support
`member 8 to accommodate the bearings 7. One end of the
`member 8 to accommodate the bearings 7. One end of the 35
`35
`shaft 6 is inserted into the bearing 7 positioned in the base 2
`shaft 6 is inserted into the bearing 7 positioned in the base 2
`and the other end of the shaft 6 is placed in the bearing 7
`and the other end of the shaft 6 is placed in the bearing 7
`located in the hub 8. A separate electrical connector 9 may
`located in the hub 8. A separate electrical connector 9 may
`also be inserted into the base 2.
`also be inserted into the base 2.
`Each of these parts must be fixed at predefined tolerances
`Each of these parts must be fixed at predefined tolerances 40
`40
`with respect to one another. Accuracy in these tolerances can
`with respect to one another. Accuracy in these tolerances can
`significantly enhance motor performance.
`significantly enhance motor performance.
`An important factor in motor design is the lowering of the
`An important factor in motor design is the lowering of the
`operating temperature of the motor. Increased motor tem
`operating temperature of the motor. Increased motor tem(cid:173)
`perature affects the electrical efficiency of the motor and
`perature affects the electrical efficiency of the motor and 45
`45
`bearing life. As temperature increases, resistive loses in wire
`bearing life. As temperature increases, resistive loses in wire
`increase, thereby reducing total motor power. Furthermore,
`increase, thereby reducing total motor power. Furthermore,
`the Arrhenius equation predicts that the failure rate of an
`the Arrhenius equation predicts that the failure rate of an
`electrical device is exponentially related to its operating tem
`electrical device is exponentially related to its operating tem(cid:173)
`perature. The frictional heat generated by bearings increases
`perature. The frictional heat generated by bearings increases 50
`50
`with speed. Also, as bearings get hot they expand, and the
`with speed. Also, as bearings get hot they expand, and the
`bearing cages get stressed and may deflect, causing non
`bearing cages get stressed and may deflect, causing non(cid:173)
`uniform rotation and the resultant further heat increase. One
`uniform rotation and the resultant further heat increase. One
`drawback with existing motor designs is their limited effec
`drawback with existing motor designs is their limited effec(cid:173)
`tive dissipation of the heat, and difficulty in incorporating
`tive dissipation of the heat, and difficulty in incorporating
`heat sinks to aid in heat dissipation. In addition, in current
`heat sinks to aid in heat dissipation. In addition, in current
`motors the operating temperatures generally increase as the
`motors the operating temperatures generally increase as the
`size of the motor is decreased.
`size of the motor is decreased.
`Electromagnetic devices used in electrical products may
`Electromagnetic devices used in electrical products may
`need to be cooled to remove heat generated by operation of
`need to be cooled to remove heat generated by operation of 60
`60
`the device. It is well known that a fluid in the environment of
`the device. It is well known that a fluid in the environment of
`the device can be used to aid cooling. As an example, a
`the device can be used to aid cooling. As an example, a
`method of cooling a motor is to include a fan on the motor
`method of cooling a motor is to include a fan on the motor
`shaft. The fan then blows air past the motor. Air, however, has
`shaft. The fan then blows air past the motor. Air, however, has
`a fairly low heat capacity, and thus cannot carry away as much
`a fairly low heat capacity, and thus cannot carry away as much
`heat as is sometime generated by the motor. Also, in some
`heat as is sometime generated by the motor. Also, in some
`applications there is no place to mount a fan. Other fluids, and
`applications there is no place to mount a fan. Other fluids, and
`
`BRIEF SUMMARY OF THE INVENTION
`BRIEF SUMMARY OF THE INVENTION
`
`Electromagnetic devices have been invented which over
`Electromagnetic devices have been invented which over(cid:173)
`come many of the foregoing problems. In one class of
`come many of the foregoing problems. In one class of
`devices, a heat transfer fluid flows through the device. In
`devices, a heat transfer fluid flows through the device. In
`another class of devices, a heat transfer fluid is contained
`another class of devices, a heat transfer fluid is contained
`within the device. Encapsulating portions of the device at the
`within the device. Encapsulating portions of the device at the
`same time a heat exchange mechanism is provided may pro
`same time a heat exchange mechanism is provided may pro-
`vide the additional benefit of protecting the parts from corro
`vide the additional benefit of protecting the parts from corro(cid:173)
`sive or otherwise damaging environments.
`sive or otherwise damaging environments.
`In a first aspect, the invention is a fluid-cooled electromag
`In a first aspect, the invention is a fluid-cooled electromag(cid:173)
`netic field-functioning device comprising at least one electri
`netic field-fnnctioning device comprising at least one electri(cid:173)
`cal conductor; a monolithic body of injection molded ther
`cal conductor; a monolithic body of injection molded ther(cid:173)
`moplastic material substantially encapsulating the at least one
`moplastic material substantially encapsulating the at least one
`conductor; and a non-linear heat transfer fluid pathway in the
`conductor; and a non-linear heat transfer fluid pathway in the
`monolithic body, with at least one fluid inlet and at least one
`monolithic body, with at least one fluid inlet and at least one
`fluid outlet to the pathway to allow for passage of heat transfer
`fluid outlet to the pathway to allow for passage of heat transfer
`fluid through the pathway.
`fluid through the pathway.
`In a second aspect, the invention is a fluid-cooled electro
`In a second aspect, the invention is a fluid-cooled electro-
`magnetic field-functioning device comprising at least one
`magnetic field-functioning device comprising at least one
`conductor and at least one inductor; a monolithic body of
`conductor and at least one inductor; a monolithic body of
`injection molded thermoplastic material substantially encap
`injection molded thermoplastic material substantially encap(cid:173)
`sulating the at least one inductor; and a non-linear heat trans
`sulating the at least one inductor; and a non-linear heat trans-
`fer fluid pathway in the monolithic body, with at least one
`55 fer fluid pathway in the monolithic body, with at least one
`55
`fluid inlet and at least one fluid outlet to the pathway to allow
`fluid inlet and at least one fluid outlet to the pathway to allow
`for passage of heat transfer fluid through the pathway.
`for passage of heat transfer fluid through the pathway.
`In a third aspect the invention is a fluid-cooled electromag
`In a third aspect the invention is a fluid-cooled electromag(cid:173)
`netic field-functioning device comprising at least one electri
`netic field-fnnctioning device comprising at least one electri(cid:173)
`cal conductor; a monolithic body of injection molded ther
`cal conductor; a monolithic body of injection molded ther(cid:173)
`moplastic material substantially encapsulating the at least one
`moplastic material substantially encapsulating the at least one
`conductor; and a non-linear heat transfer fluid pathway in the
`conductor; and a non-linear heat transfer fluid pathway in the
`monolithic body, with at least one fluid inlet and at least one
`monolithic body, with at least one fluid inlet and at least one
`fluid outlet to the pathway to allow for passage of heat transfer
`fluid outlet to the pathway to allow for passage of heat transfer
`fluid through the pathway, and wherein the monolithic body
`65 fluid through the pathway, and wherein the monolithic body
`65
`completely covers the exterior of the device except for fluid
`completely covers the exterior of the device except for fluid
`inlet and fluid outlet.
`inlet and fluid outlet.
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1001-0016
`
`

`

`US 7,683,509 B2
`US 7,683,509 B2
`
`4
`4
`BRIEF DESCRIPTION OF SEVERAL VIEWS OF
`BRIEF DESCRIPTION OF SEVERAL VIEWS OF
`THE DRAWINGS
`THE DRAWINGS
`
`3
`3
`In another aspect, the invention is a fluid-cooled electro
`In another aspect, the invention is a fluid-cooled electro(cid:173)
`magnetic field-functioning device comprising one or more
`magnetic field-functioning device comprising one or more
`electrical conductors; a heat transfer fluid confinement mem
`electrical conductors; a heat transfer fluid confinement mem(cid:173)
`ber; and a monolithic body of phase change material substan
`ber; and a monolithic body of phase change material substan(cid:173)
`tially encapsulating both the one or more conductors and the
`tially encapsulating both the one or more conductors and the
`heat transfer fluid confinement member.
`heat transfer fluid confinement member.
`In yet another aspect the invention is a fluid-cooled elec
`In yet another aspect the invention is a fluid-cooled elec(cid:173)
`tromagnetic device comprising an assembly comprisingi) an
`tromagnetic device comprising an assembly comprising i) an
`inductor in operable proximity to at least one conductor that
`inductor in operable proximity to at least one conductor that
`creates at least one magnetic field when electrical current is
`creates at least one magnetic field when electrical current is
`conducted by the conductor; and ii) a body of a phase change
`conducted by the conductor; and ii) a body of a phase change
`material substantially encapsulating the conductor; and at
`material substantially encapsulating the conductor; and at
`least one liquid-tight coolant channel substantially encapsu
`least one liquid-tight coolant channel substantially encapsu(cid:173)
`lated within the body of phase change material.
`lated within the body of phase change material.
`15
`In still another aspect the invention is a fluid-cooled elec
`In still another aspect the invention is a fluid-cooled elec- 15
`tromagnetic field-functioning device comprising an inductor
`tromagnetic field-functioning device comprising an inductor
`and at least one conductor that creates at least one magnetic
`and at least one conductor that creates at least one magnetic
`field when electrical current is conducted by the conductor; a
`field when electrical current is conducted by the conductor; a
`heat transfer fluid confinement member containing a heat
`heat transfer fluid confinement member containing a heat
`20
`transfer fluid; and a monolithic body of phase change material
`transfer fluid; and a monolithic body of phase change material 20
`substantially encapsulating at least one of the inductor and the
`substantially encapsulating at least one of the inductor and the
`at least one conductor, the monolithic body being in thermal
`at least one conductor, the monolithic body being in thermal
`contact with the heat transfer fluid.
`contact with the heat transfer fluid.
`A further aspect of the invention is a method of making a
`A further aspect of the invention is a method of making a 25
`25
`fluid-cooled electromagnetic field-functioning device com
`fluid-cooled electromagnetic field-functioning device com(cid:173)
`prising the steps of providing a core assembly comprising an
`prising the steps of providing a core assembly comprising an
`inductor and at least one conductor that creates at least one
`inductor and at least one conductor that creates at least one
`magnetic field when electrical current is conducted by the
`magnetic field when electrical current is conducted by the
`conductor, substantially encapsulating at least one of the
`conductor, substantially encapsulating at least one of the
`inductor and the at least one conductor in a body of phase
`inductor and the at least one conductor in a body of phase
`change material; providing a heat transfer fluid confinement
`change material; providing a heat transfer fluid confinement
`chamber in the body of phase change material; and, adding a
`chamber in the body of phase change material; and, adding a
`heat transfer fluid to the confinement chamber and sealing the
`heat transfer fluid to the confinement chamber and sealing the
`chamber to retain the heat transfer fluid in the chamber.
`chamber to retain the heat transfer fluid in the chamber.
`In another aspect the invention is a method of cooling an
`In another aspect the invention is a method of cooling an
`electromagnetic field-functioning device wherein the electro
`electromagnetic field-functioning device wherein the electro(cid:173)
`magnetic field-functioning device comprises one or more
`magnetic field-functioning device comprises one or more
`electrical conductors and a monolithic body of phase change
`electrical conductors and a monolithic body of phase change
`material substantially encapsulating the one or more conduc
`material substantially encapsulating the one or more conduc- 40
`40
`tors, wherein a heat transfer fluid flows through a confined
`tors, wherein a heat transfer fluid flows through a confined
`path substantially within the body of phase change material to
`path substantially within the body of phase change material to
`transfer heat away from the conductors.
`transfer heat away from the conductors.
`In one embodiment, a motor can be cooled by using a heat
`In one embodiment, a motor can be cooled by using a heat
`pipe embedded in a body of phase change material that also
`pipe embedded in a body of phase change material that also
`substantially encapsulates parts of the motor. In another
`substantially encapsulates parts of the motor. In another
`embodiment, a motor can be cooled by passing liquid through
`embodiment, a motor can be cooled by passing liquid through
`a coolant channel encased in the body of phase change mate
`a coolant chaunel encased in the body of phase change mate(cid:173)
`rial also substantially encapsulating the motor component.
`rial also substantially encapsulating the motor component.
`The body of phase change material provides a path for the
`The body of phase change material provides a path for the 50
`50
`heat to be transferred from the stator to the liquid coolant,
`heat to be transferred from the stator to the liquid coolant,
`where it can be carried away. The liquid is also confined, so
`where it can be carried away. The liquid is also confined, so
`that it does not contact other parts of the motor or get ran
`that it does not contact other parts of the motor or get ran(cid:173)
`domly discharged from the motor. Besides motors, other elec
`domly discharged from the motor. Besides motors, other elec(cid:173)
`tromagnetic field function devices may be made with coolant
`tromagnetic field function devices may be made with coolant 55
`55
`channels. The flow path or chamber for the coolant may be
`channels. The flow path or chamber for the coolant may be
`formed by injecting gas into the molten thermoplastic after it
`formed by injecting gas into the molten thermoplastic after it
`has been injected into a mold but before it solidifies to form
`has been injected into a mold but before it solidifies to form
`the body encapsulating the motor component, or component
`the body encapsulating the motor component, or component
`of other electromagnetic field-functioning devices. The fore
`of other electromagnetic field-functioning devices. The fore-
`going and other features, and the advantages of the invention,
`going and other features, and the advantages of the invention,
`will become further apparent from the following detailed
`will become further apparent from the following detailed
`description of the presently preferred embodiments, read in
`description of the presently preferred embodiments, read in
`conjunction with the accompanying drawings. The detailed
`conjunction with the accompanying drawings. The detailed
`description and drawings are merely illustrative of the inven
`description and drawings are merely illustrative of the inven- 65
`65
`tion and do not limit the scope of the invention, which is
`tion and do not limit the scope of the invention, which is
`defined by the appended claims and equivalents thereof.
`defined by the appended claims and equivalents thereof.
`
`5
`
`FIG. 1 is an exploded, partial cross-sectional and perspec
`FIG. 1 is an exploded, partial cross-sectional and perspec(cid:173)
`tive view of a prior art high speed motor.
`tive view of a prior art high speed motor.
`FIG. 2 is a perspective view of a stator used in a first
`FIG. 2 is a perspective view of a stator used in a first
`embodiment of the present invention.
`embodiment of the present invention.
`FIG. 3 is an exploded, partial cross-sectional and perspec
`FIG. 3 is an exploded, partial cross-sectional and perspec(cid:173)
`tive view of a high speed motor in accordance with a first
`tive view of a high speed motor in accordance with a first
`embodiment of the present invention.
`10 embodiment of the present invention.
`10
`FIG. 4 is a cross-sectional view of the high speed motor of
`FIG. 4 is a cross-sectional view of the high speed motor of
`FIG. 3.
`FIG. 3.
`FIG. 5 is a schematic drawing of a mold used to make the
`FIG. 5 i