Study of an Active Heat‐Dissipating Liquid Metal Wire with Electrical‐Material Cotransmission Characteristics and Its Applications

In the field of precision motors, there is a growing demand for higher power density, requiring wires to withstand elevated current density and resulting,in significant heating of the motor. This study investigates various properties of liquid metal conductors and evaluates their potential for enhancing the heat dissipation performance in a motor armature system. The results demonstrate that liquid metal conductors can be successfully applied to a motor armature system. Their characteristics, such as electrohydraulic coupling and decoupling, fulfill the requirements of fluid field circulation and unidirectional electrical conduction in the armature system. With a current density of 176.8 mA cm−2, the maximum temperature decreases from 35.2 to 30.9 °C, achieving a temperature reduction of 12%. This article details the specific methods for manufacturing motor armatures using liquid metal conductors, including the structures of different types of armature systems. Additionally, the article also presents a study on some performance aspects of this armature system, showing a decrease in the maximum temperature from 54.9 to 50.9 °C, corresponding to a 7.3% temperature reduction. Thus, a novel approach is provided to the thermal management system of motors, which can be further extended to the field of bioelectrodes in future research. The main components of the armature winding cooling system are the peristaltic pump, the liquid metal conductor, and the droplet decoupler. Among them, liquid metal has the function of collaborative transmission of electrical materials. The droplet decoupler is responsible for the decoupling of electrolysis and fluid circulation. Peristaltic pumps power the movement of liquid metal throughout the system.