Direct Conduction Cooling (DCC)

The power density of electric motors used in EVs is very important. Generally, the higher the power density the smaller the motor needed to provide the EV with the performance needed by the OEM. The smaller the motor the lower the manufacturing cost and the higher the efficiency at low power which extends range. Many factors affect the power density and one of the most important is the effectiveness of the cooling system. Most OEM are using what is referred to as a radial flux motor that consists of a stationary tubular stator enclosing a rotating cylindrical rotor. The stator is wound with strands of copper wire that creates a rotating magnetic field that “drags” the rotor around creating torque and power. The rotor is fitted with powerful magnets (synchronous motor) or aluminium/copper conductors (asynchronous motor), but both types use the same stator.

Most OEMs are adopting a type of winding called “hairpins” " rel="nofollow" target="_blank">https://www.youtube.com/watch?v=pmWFt0_RUoU as in the Porsche Taycan. They then spray oil onto the ends of the hairpins to cool them and get the maximum power density out of the motor . You can see this discussed 9 minutes into this teardown video " rel="nofollow" target="_blank">https://www.youtube.com/watch?v=mHVV52lPyIs&t=764s . The only OEM not currently using this spray system that we know of, is VW (APP 310 motor) and they end up with a very low power density somewhat inefficient motor. To facilitate the endspray system you need a motor, a pump, a control system, a filter, a heat exchanger and complex plumbing. In Porsche Taycan’s case they add another radiator. The cost of the system in the Ford Mach-E rear motor is estimated at over $150.

The DCC method uses passive conduction to pull heat out of the end-windings. The NCAP solution is specifically designed for hairpin motors and can match or better the expensive end-spray systems . The cost of the NCAP system estimated by our manufacturing partner Demak Group https://chargedevs.com/newswire/ev-hev-traction-motor-encapsulation-with-demak-group-technologies/ is under $30.00.

This is what we intend to “sell” to the market offering a $120 saving for a negotiated royalty of up to $10. We believe that over time we can convert a large proportion of the market from end spray to DCC with the focus on The NCAP/ hairpin solution. The market size will arguably become >50 million motors per annum by 2030.

Intellectual property status

Patent already applied for

Patent application number : Patent 2021904298 Applied on 31st Dec 2021

Where : Provisional in Australia

Current development status

Commercially available technologies

Use of Proceeds

Re require funding for marketing collateral and promotion that includes more work on product specific applications. • Website $15,000) • Magazine Advertising ($80,000 /annum) • Marketing Personel (new employee) who will need to travel and negotiate ($110,000/annum) • Repayment of loans associated with development costs so far (AUD 300,000) These can be delayed to some extent. • Ongoing supporting expenses around (AUD60,000/annum) • Patent expenses only arise after 9 months We will try hard to ensure that any external consultant input is covered by prospective customers. This may also include positive cashflow into this company. We will have to sustain for 12 months We are not yet putting a value on the technology and expect any investment to be contingent on both quantum and speed of success.