Efficient cooling of commercially available electrical wiring by the use of metals with low melting temperatures

We offer a new approach to produce electrical wiring for electromagnetic coils that can be efficiently cooled.

We use commercial available insulated wires and embed these wires into conductive low melt temperature metals (LMTM) such as tin containing alloys. We use vacuum casting technique for the wire embedding to achieve full thermal contact between the cooling channel and the wires. Due to excellent heat conduction properties of the LMTM, the operation induced heat is immediately transferred to the cooling channel although it is spatially separated from the wire. Electrical wiring produced according to out technology can be used for the fabrication for high power electromagnetic coils with different dimensions and designs. The location of the cooling channel can be spatially adjusted. Even more, multiple cooling channels can be implemented into the wiring to achieve higher cooling rates. The sketch and the photograph of the electromagnetic coil prepared as described above are shown in the Fig. 1.

Our results show that the original wire insulation made of polyimide or polyester is sufficient to avoid short-circuit and the electromagnetic coils fabricated according to this method can be used in high power electromagnetic coils.
Advantages

• Fast and low-cost manufacturing by means of vacuum casting
• Usage of commercial available polyimide or polyester insulated wires/cables
• Fully cooled high electrical power density electrical wires
• Adjustable cooling power and design
• Applicability in coils with high magnetic field as well as with pulsed operation

• DE patent application (DE102014017857B3) granted in February 2016.
• PCT patent application filed in November 2015.