Abstract
In this article, a novel form of thermal interface material (TIM), represented by three industrially manufactured pressure-sensitive adhesive (PSA) tapes with electrical insulating properties, is characterized regarding its applicability in an electric motor with air-gap winding. Firstly, the adhesion performances, in terms of the winding process, were investigated experimentally. Here, every TIM shows sufficient shear strength for the wire–TIM joints, as well as peel adhesion to the laminated iron core. Secondly, the thermal–physical properties of the TIMs are inspected experimentally via laser flash analysis (LFA) and differential scanning calorimetry (DSC). For every TIM, the value of the thermal resistance can double if the relatively smooth surface (Ra = 0.2 μm) of the adjacent layers is interchanged with a rougher one (Ra = 2.0–3.7 μm). Additionally, the TIM’s performance at the system level is examined. Therefore, a flat test section, according to the specifications of the original motor, is studied experimentally and numerically utilizing infrared (IR) thermography and the finite element method (FEM). The focus is set on the heat flow and temperature distribution in the test section under varying thermal loads, mass flow, and variety of TIMs.
Highlights
An increased power-to-mass ratio is highly demanded in mobile applications, such as automotive and aviation cases
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Summary
An increased power-to-mass ratio is highly demanded in mobile applications, such as automotive and aviation cases. Electric motors applying an air-gap winding, as shown, can achieve these demands through minimization of the acquired iron mass [1]. In areas with actual mechanical contact can a conductive heat transfer path emerge. This leaves gaps filled with air, in which the thermal conductivity is smaller by orders of magnitude, and results in a significant temperature jump across the solid contact interface (see Section 2). 2022, 13, 42 thermal conductivity conductivity is is smaller smaller by by orders orders of of magnitude, magnitude, and and results results in in aa significant significant thermal temperature jump across the solid contact interface TIMs have temperature jump across the solid contact interface (see Section 2).
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