Novel Application of Advanced Spray Cooling Thermal Management for Integrated Controller-Motors

70171 The continuing trend toward the development of smaller, lighter, and less costly propulsion systems for advanced Hybrid Electric Vehicles continues to advance beyond the capabilities of commercially available thermal management systems. Currently available motors that use water in forced convection cooling systems offer only one-fifth of the required power density. This project will apply high heat flux spray cooling technology to develop an advanced thermal management system for integrated traction drive controller-motors. Phase I will focus on the mechanical modeling and finite element analysis of a spray cooled permanent magnet brushless motor with integral drive electronics. Technical issues associated with sealing and power electronics packaging will be addressed. Phase II will result in a tested prototype with integral controller-motor and thermal management meeting the requirements for future Electric Vehicles and Hybrid Electric Vehicles. Commercial Applications and Other Benefits as described by the awardee: Advances in state-of-the-art electric motor and drive systems for the next class of Hybrid Electric Vehicles and Electric Vehicles are hindered by the limited capabilities of traditional packaging and cooling. High heat flux spray cooling should reduce the size and weight of electric drive components for the automotive industry, thereby addressing the need for lighter vehicles for improved fuel economy.