Enhanced Motor Performance via Two-Phase Thermal Management

Thermal management presents a significant constraint on the achievable efficiency and power density of MW-scale electric motors for aircraft propulsion. High temperatures within the windings limit the maximum power density, reduce the lifetime of the winding insulation, and increase electrical losses resulting in lower efficiency. Innovative thermal management strategies can significantly enhance the performance of motors for electrified aircraft propulsion. In this SBIR program, Advanced Cooling Technologies, Inc. (ACT) is developing an innovative two-phase thermal transport system for high power electric motors that will augment traditional cooling solutions by efficiently extracting heat from difficult to cool areas. The two-phase thermal transport system will be fully passive, lightweight and scalable. The proposed technologies will improve waste heat rejection from motor windings allowing for increased power density and efficiency. The Phase I program successfully demonstrated the feasibility of the concept and presented an electric motor with a 60% increase in power density over a conventional design with comparable thermal performance. In the Phase II program, ACT will continue to lead the development and maturation of an innovative two-phase heat-transfer-based thermal management solution for electric motors. The goal of the Phase II program is to demonstrate an optimized design of an enhanced motor capable of power density of 20 kW/kg and efficiency of at least 98%.nbsp;