Thermal Management System for a Vehicle Power Inductor Assembly

Abstract

The present disclosure provides a "thermal management system for a vehicle power inductor assembly". A power inductor assembly is provided, which includes a power inductor, a vehicle component, and a pair of distribution ducts. The power inductor has a housing that supports a pair of coils. The vehicle component is located above the pair of coils. Each of the pair of distribution ducts is oriented relative to one of the pair of coils below the vehicle component and has one or more openings adjacent to the coil to distribute coolant to the coil. Each of the one or more openings may define one of a circular shape or a slot shape. The size of each of the one or more openings may be set such that the exiting coolant substantially uniformly covers the adjacent coil.

Description

Technical Field

[0001] The present disclosure relates to a thermal management system for a vehicle power inductor. Background Art

[0002] The coils of vehicle inductors generate heat during operation. This heat causes power losses in the vehicle inductors. Known inductor thermal management systems rely on heat plates to help manage the thermal conditions of the vehicle inductors. However, these systems may not be of optimal efficiency and typically use potting compounds to transfer heat from the coils to the heat plate in an indirect cooling scheme. Summary of the Invention

[0003] A power inductor assembly includes a power inductor, a vehicle component, and a pair of distribution ducts. The power inductor has a housing that supports a pair of coils. The vehicle component is located above the pair of coils. Each of the pair of distribution ducts is oriented relative to one of the pair of coils below the vehicle component and has one or more openings adjacent to the coil to distribute coolant to the coil. Each of the one or more openings can define one of a circular shape and a slot shape. The size of each of the one or more openings can be set such that the exiting coolant substantially uniformly covers the adjacent coil. Each of the pair of distribution ducts can be spaced apart from one of the pair of coils, and the length of the spacing is approximately equal to one-half to five times the diameter of one of the one or more openings. The vehicle component can be one of a part of a transmission housing, a part of a support fixture for an electric motor or a generator, a power inductor, and a variable voltage controller housing. The power inductor can define a rectangular prism, and each of the pair of coils can be located above the rectangular prism and below the vehicle component. The coolant can be one of engine oil, transmission oil, and engine coolant.

[0004] The power inductor assembly includes a power inductor and two distribution ducts. The power inductor includes a housing that supports a pair of coils. Each of the two distribution ducts is oriented perpendicular to the coils. Each of the distribution ducts is arranged with one of the coils such that the coolant exiting the distribution duct covers a first predetermined area of one of the pair of coils. The first predetermined area is further defined as an area that substantially uniformly covers one of the pair of coils. The assembly may further include a third distribution duct and a fourth distribution duct. The third distribution duct may be spaced apart from one of the two distribution ducts and oriented perpendicular to one of the pair of coils for coolant distribution over the pair of coils. The fourth distribution duct may be spaced apart from the other of the two distribution ducts and oriented perpendicular to the other of the pair of coils for coolant distribution over the pair of coils. The assembly may further include a coolant pump, a sensor, and a controller. The coolant pump may be in fluid communication with one of the two distribution ducts. The sensor may communicate with one of the pair of coils to monitor the thermal condition of the pair of coils. The controller may communicate with the sensor to receive a signal including the monitored thermal condition and communicate with the coolant pump to direct the operation of the coolant pump based on the monitored thermal condition. The assembly may include an attachment sized to be mounted to an end of one of the distribution ducts, the attachment including a passage in fluid communication with the one of the distribution ducts and one or more openings in fluid communication with the passage to disperse the coolant around one of the pair of coils to cover a second predetermined area larger than the first predetermined area. The assembly may include a cap sized to be mounted to an end of one of the distribution ducts, the cap including a passage shaped to spread the coolant traveling therethrough and exiting the distribution duct. The assembly may include a vehicle component. The pair of coils and the housing may be sized to be located within a rectangular prism, and the vehicle component may be located outside the rectangular prism. The distribution ducts may be arranged with the vehicle component to provide coolant to the pair of coils without contacting the vehicle component.

[0005] The power inductor assembly includes a power inductor and an inductor thermal management system. The power inductor includes a coil pair for generating energy to help power a vehicle. The inductor thermal management system includes a coolant circuit in fluid communication with a pair of distribution ducts spaced above respective ones of the coil pair. Each of the pair of distribution ducts defines an opening for delivering coolant directly onto respective ones of the coil pair and is spaced from a corresponding one of the coils. Each of the pair of distribution ducts may be oriented vertically relative to respective ones of the coil pair such that each of the openings is disposed with respective ones of the coil pair to distribute coolant substantially uniformly over the coil pair. Each of the pair of distribution ducts may be oriented vertically relative to respective ones of the coil pair such that a gap is provided for positioning vehicle components outside of each of the distribution ducts and above the coil pair. Each of the pair of distribution ducts may be oriented horizontally relative to respective ones of the coil pair such that each of the openings is disposed with respective ones of the coil pair to distribute coolant substantially uniformly over the coil pair. Each of the pair of distribution ducts may be oriented horizontally relative to respective ones of the coil pair to provide a gap for positioning vehicle components above the pair of distribution ducts and a rectangular prism region defined by the power inductor. The coolant may be one of engine oil, transmission oil, and engine coolant. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a schematic view of an example of an electrified vehicle.

[0007] Figure 2 is a schematic view of a variable voltage converter and a power inverter.

[0008] Figure 3 is a perspective view of a portion of an example of an inductor assembly.

[0009] Figure 4 is Figure 3 a top plan view of a portion of the inductor assembly of

[0010] Figure 5A is Figure 3 a side view of a portion of the inductor assembly of , showing a vehicle component positioned adjacent thereto.

[0011] Figure 5B is a block diagram of an example of an electrified vehicle and a control system.

[0012] Figure 5C is Figure 3 a top plan view of a portion of the inductor assembly of , showing an example of the distribution duct location and coolant flow.

[0013] Figure 6Perspective view of an example of an attachment member for a distribution duct for use with an inductor assembly.

[0014] Figure 7 is Figure 3 a portion of the inductor assembly and Figure 6 top plan view of the attachment member.

[0015] Figure 8 Perspective view of a portion of an example of an inductor assembly.

[0016] Figure 9 is Figure 8 top plan view of a portion of the inductor assembly.

[0017] Figure 10 is Figure 8 side view of a portion of the inductor assembly, shown with a vehicle component positioned adjacent to the portion. DETAILED DESCRIPTION

[0018] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and other embodiments may take various forms and alternative forms. The figures are not necessarily drawn to scale; some features may be enlarged or minimized to show details of particular components. Thus, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one skilled in the art to employ the invention in different ways. As will be understood by one of ordinary skill in the art, the various features shown and described with reference to any one of the figures may be combined with features shown in one or more other figures to produce embodiments not explicitly shown or described. Combinations of the shown features provide representative embodiments for typical applications. However, various combinations and modifications of the described features consistent with the teachings of the present disclosure may be desired for a particular application or implementation.

[0019] Figure 1 An example of an electrified vehicle is shown and generally referred to herein as vehicle 16. Vehicle 16 may include a transmission 12 and is an example of an electric vehicle propelled by an electric machine 18 with the assistance of an internal combustion engine 20. Vehicle 16 may be connected to an external power grid. The electric machine 18 may be an AC electric motor depicted as motor 18 in Figure 1 The electric machine 18 receives electrical power and provides torque for vehicle propulsion. The electric machine 18 may also be used as a generator to convert mechanical power into electrical power through regenerative braking.

[0020] The transmission 12 may be a power-split configuration. The transmission 12 may include a first electric machine 18 and a second electric machine 24. The second electric machine 24 may be the one depicted as Figure 1The AC electric motor depicted as generator 24 in. Similar to the first motor 18, the second motor 24 can receive power and provide output torque. The second motor 24 can also operate as a generator for converting mechanical power into electrical power and optimizing the power flow through the transmission 12. In other embodiments, the transmission may not have a power split configuration.

[0021] The transmission 12 can include a planetary gear unit (not shown) and can operate as a continuously variable transmission without any fixed or step ratio. The transmission 12 can also include an overrunning clutch (O.W.C.) and a generator brake 33. The O.W.C. can be coupled to the output shaft of the engine 20 to control the direction of rotation of the output shaft. The O.W.C. can prevent the transmission 12 from driving the engine 20 in reverse. The generator brake 33 can be coupled to the output shaft of the second motor 24. The generator brake 33 can be activated to "brake" or prevent the rotation of the output shafts of the second motor 24 and the central gear 28. Alternatively, the O.W.C. and the generator brake 33 can be replaced by implementing control strategies for the engine 20 and the second motor 24. The transmission 12 can be connected to a drive shaft 46. The drive shaft 46 can be coupled to a pair of drive wheels 48 through a differential 50. An output gear (not shown) of the transmission can assist in transmitting torque between the transmission 12 and the drive wheels 48. The transmission 12 can also be in communication with a heat exchanger 49 or an automatic transmission fluid cooler (not shown) to cool the transmission fluid.

[0022] The vehicle 16 includes an energy storage device, such as a traction battery 52 for storing electrical energy. The battery 52 can be a high-voltage battery capable of outputting power to operate the first motor 18 and the second motor 24, as further described below. The battery 52 can also receive power from the first motor 18 and the second motor 24 when they operate as generators. The battery 52 can be a battery pack composed of a number of battery modules (not shown), where each battery module contains a plurality of battery cells (not shown). Other embodiments of the vehicle 16 anticipate alternative types of energy storage devices, such as capacitors and fuel cells (not shown) that can supplement or replace the battery 52.

[0023] A high-voltage bus can electrically connect the battery 52 to the first motor 18 and the second motor 24. For example, the vehicle 16 can include a battery energy control module (BECM) 54 for controlling the battery 52. The BECM 54 can receive inputs indicating certain vehicle conditions and battery conditions such as battery temperature, voltage, and current. The BECM 54 can calculate and estimate parameters of the battery 52, such as the battery state of charge (BSOC) and the battery power capacity (Pcap). The BECM 54 can provide outputs indicating the BSOC and the Pcap to other vehicle systems and controllers.

[0024] Vehicle 16 may include a DC-DC converter or variable voltage converter (VVC) 10 and an inverter 56. The VVC 10 and the inverter 56 may be electrically connected between the battery 52 and the first motor 18 and the second motor 24. The VVC 10 may "boost" or increase the voltage potential of the power supplied by the battery 52. The VVC 10 may also "buck" or decrease the voltage potential of the power supplied to the battery 52. The inverter 56 may convert the DC power supplied by the battery 52 into AC power via the VVC 10 to operate each of the motors 18 and 24. The inverter 56 may also rectify the AC power provided by each of the motors 18 and 24 into DC for charging the battery 52. In other examples, the transmission 12 may operate with multiple inverters, such as one inverter associated with each of the motors 18 and 24. The VVC 10 includes an inductor assembly 14 (further described with respect to Figure 2 ).

[0025] The transmission 12 is shown communicating with a transmission control module (TCM) 58 for controlling the motors 18 and 24, the VVC 10, and the inverter 56. The TCM 58 may be configured to monitor the conditions of each of the motors 18 and 24, such as position, speed, and power consumption. The TCM 58 may also monitor the electrical parameters (e.g., voltage and current) at various locations within the VVC 10 and the inverter 56. The TCM 58 provides an output signal corresponding to this information for use by other vehicle systems.

[0026] Vehicle 16 may include a vehicle system controller (VSC) 60 that communicates with other vehicle systems and controllers to coordinate their operation. Although shown as a single controller, it should be anticipated that the VSC 60 may include multiple controllers to control multiple vehicle systems and components according to an overall vehicle control logic or software.

[0027] Vehicle controllers (such as VSC 60 and TCM 58) can include various configurations of microprocessors, application specific integrated circuits, integrated circuits, memories (e.g., flash, read-only memory, random access memory, erasable programmable read-only memory, and / or electrically erasable programmable read-only memory), and software code to cooperate with each other to perform vehicle operations. The controller can also include predetermined data or a "look-up table" that can be accessed from the memory and can be based on computational and test data. The controller can utilize this predetermined data to facilitate the control of vehicle operations. VSC 60 can communicate with other vehicle systems and controllers (e.g., BECM 54 and TCM 58) via one or more wired or wireless connections using bus protocols such as Controller Area Network and Local Interconnect Network. VSC 60 can receive an input (pseudo-random number (PRND)) representing the current position of the transmission 12 (e.g., park, reverse, neutral, or drive). VSC 60 can also receive an input (APP) representing the accelerator pedal position. VSC 60 can provide outputs representing desired wheel torque, desired engine speed, and generator braking commands to TCM 58; and provide contactor control to BECM 54.

[0028] Vehicle 16 can include an engine control module (ECM) 64 for controlling engine 20. VSC 60 provides an output such as desired engine torque to ECM 64, which can be based on a plurality of input signals including APP and can correspond to the driver's request for vehicle propulsion.

[0029] Battery 52 can periodically receive AC energy from an external power source or the power grid via charging port 66. Vehicle 16 can also include an on-board charger 68 that receives AC energy from charging port 66. Charger 68 can include AC / DC conversion capabilities for converting the received AC energy into DC energy suitable for charging battery 52 during a recharge operation. Although shown and described in the context of a PHEV (plug-in hybrid electric vehicle), it should be anticipated that inverter 56 can be implemented in other types of electrified vehicles such as an FHEV (full hybrid electric vehicle) or a BEV (battery electric vehicle).

[0030] Figure 2An example of the electrical schematic diagram of the VVC 10 and the inverter 56 is shown. The VVC 10 may include a first switch unit 70 and a second switch unit 72 for boosting the input voltage (V_bat) to provide an output voltage (V_dc). The first switch unit 70 is shown where a first transistor 74 is connected in parallel to a first diode 76 and its polarity is switched (referred to herein as anti-parallel). The second switch unit 72 is shown where a second transistor 78 is anti-parallel connected to a second diode 80. Each of the transistors 74 and 78 can be a controllable switch (e.g., an insulated gate bipolar transistor (IGBT) or a field effect transistor (FET)). Additionally, each of the transistors 74 and 78 can be individually controlled by the TCM 58. The inductor assembly 14 is depicted as an input inductor connected in series between the battery 52 and the switch units 70 and 72. When current is supplied, the inductor assembly 14 can generate a magnetic flux. When the current flowing through the inductor assembly 14 changes, a time-varying magnetic field is generated and a voltage is induced. Other embodiments of the VVC 10 may include alternative circuit configurations (e.g., more than two switches).

[0031] The inverter 56 may include a plurality of half-bridges 82 stacked in the assembly. Each of the half-bridges 82 can be encapsulated as a power stage. In the example shown, the inverter 56 includes six half-bridges (although Figure 2 only one complete half-bridge 82 is labeled), three for the motor 18, and three for the generator 24. Each of the half-bridges 82 may include a positive DC lead 84 coupled from the battery 52 to the positive DC node and a negative DC lead 86 coupled from the battery 52 to the negative DC node. Each of the half-bridges 82 may also include a first switch unit 88 and a second switch unit 90. The first switch unit 88 includes a first transistor 92 connected in parallel to a first diode 94. The second switch unit 90 includes a second transistor 96 connected in parallel to a second diode 98. The first transistor 92 and the second transistor 96 can be IGBTs or FETs. The first switch unit 88 and the second switch unit 90 of each of the half-bridges 82 convert the DC power of the battery 52 into a single-phase AC output at the AC leads 100. Each of the AC leads 100 is electrically connected to the motor 18 or the generator 24. In this example, three of the AC leads 100 are electrically connected to the motor 18, and the other three AC leads 100 are electrically connected to the generator 24.

[0032] Components of the VVC and the inverter can be heated and / or cooled using a liquid thermal management system, an air thermal management system, or other methods known in the art. In one example of a liquid thermal management system, a hot plate can be in thermal communication with components of the VVC or the inverter. A system, such as a pressurization system, can control the coolant flow through the hot plate to help dissipate heat from the components, such as heat generated during voltage conversion. The thermal management system can be arranged with and / or supported by the power module assembly such that the hot plate is in thermal communication with the components to facilitate cooling thereof by the coolant.

[0033] Figure 3 and Figure 4 An example of a portion of a power inductor assembly, referred to herein as inductor assembly 200, is shown. Inductor assembly 200 can operate within a vehicle system 202 that includes a thermal circuit (shown in Figure 5B ). Inductor assembly 200 can include a housing 204, a pair of coils 206, and one or more distribution ducts 208. The housing 204 and the pair of coils 206 can be sized to fit within a volume defined by a rectangular prism 209. The housing 204 can support the pair of coils 206 and define a cavity 210 sized to receive a portion of each of the pair of coils 206.

[0034] Each of the distribution ducts 208 is oriented perpendicular to the pair of coils 206, as shown in Figure 3 . Each of the distribution ducts 208 can be in fluid communication with a coolant pump (not shown in Figure 3 and Figure 4 ) and mounted to a vehicle component located near the pair of coils 206. For example, each of the distribution ducts 208 can be mounted to a portion of a transmission housing, a portion of a support fixture for an electric motor or generator, an inductor, or a VVC housing.

[0035] Coolant 212 can flow out of each of the distribution ducts 208 and contact a portion of one of the pair of coils 206 to help manage the thermal condition of the coil pair. For example, coolant 212 can contact the pair of coils 206 and cover a predetermined area 213. The predetermined area 213 can be selected based on a portion of the pair of coils 206 where heat accumulates at temperatures outside of the optimal operating conditions during operation. It should be anticipated that coolant 212 can also be distributed to cover all or substantially all of each of the pair of coils 206. Each of the distribution ducts 208 can be spaced apart from one of the pair of coils 206 by a length approximately equal to the diameter of the opening of the distribution duct 208. In another example, each of the distribution ducts 208 can be spaced apart from one of the pair of coils 206 by a length approximately equal to one-half to five times the diameter of the opening of the distribution duct 208.

[0036] Figure 5A The positional relationship of the distribution pipe 208 relative to the pair of coils 206 and the rectangular prism 209 is also shown. For example, one or more vehicle components 233, 235, or 237 may limit the available packaging space adjacent to the inductor assembly 200. In this example, the distribution pipe 208 is horizontally oriented relative to the pair of coils 206 to provide space for one or more vehicle components 233, 235, or 237. Examples of one or more vehicle components 233, 235, or 237 include a portion of a transmission housing, a portion of a support fixture for an electric motor or generator, an inductor, or a VVC housing.

[0037] During operation of the inductor assembly 200, the temperature of each of the pair of coils 206 may increase. Each of the pair of connectors 216 may be electrically connected to one of the pair of coils 206 to deliver current to the coil pair. The coolant 212 may help cool each of the pair of coils 206 to keep the temperature within a predetermined threshold to affect optimal operating conditions. Although the predetermined threshold may vary based on operating conditions, coolant selection, and coil type, in one example, the predetermined threshold may be between -50 degrees Celsius and 220 degrees Celsius. In another example, the predetermined threshold may be between 20 degrees Celsius and 150 degrees Celsius. The distribution pipe 208 may be arranged with the pair of coils 206 to evenly distribute the coolant 212 substantially uniformly over the pair of coils 206. For example, the coolant 212 may be distributed to substantially cover each of the pair of coils 206. The flow rate of the coolant 212 may be consistent or selectively varied to provide an optimal distribution of the coolant 212 to the pair of coils 206.

[0038] For example and now additionally referring Figure 5B , one or more sensors 211 may be in thermal communication with each of the pair of coils 206 of the inductor assembly 200 to monitor the condition of the coil pair. One or more temperature sensors 211 may transmit the monitored temperature to the controller 214 via a signal. The controller 214 may communicate with the coolant pump 215 to adjust the flow rate of the coolant 212 flowing to the inductor assembly 200 in response to the received signal to maintain an optimal thermal condition of the pair of coils 206, such as keeping the temperature of the pair of coils 206 within a predetermined threshold. For example, the controller 214 may direct the coolant pump 215 to increase the flow rate of the coolant 212 to the pair of coils 206 in response to receiving a signal from one or more sensors 211 indicating that the temperature of the pair of coils 206 exceeds the predetermined threshold.

[0039] The base portion of the cavity 210 may collect the coolant 212 after contacting each of the pair of coils 206. One or more return pipes (not shown) may lead to the cavity 210 to remove the coolant 212 collected therein.

[0040] Figure 5C Shows the spatial relationship between each of the distribution ducts 208 and each of the coil pairs 206. The position of the center point of each of the distribution ducts 208 can be based on the spacing from the side of the corresponding coil 206. For example, dimension 220 represents the length between the first side of one of the coil pairs 206 and the center point of one of the distribution ducts 208. In one example, dimension 220 can be a length between half and three times the opening diameter of the distribution duct. Dimension 222 represents the length between the second side of one of the coil pairs 206 and the center point of one of the distribution ducts 208.

[0041] Figure 6 and Figure 7 Shows an example of an attachment 230 for one of the distribution ducts 208 to assist in selectively distributing the coolant 212 to one of the coil pairs 206. The attachment 230 can be arranged with one of the coil pairs 206 to distribute the coolant 212 over one of the coil pairs 206 to cover a portion or substantially all of the coil pair 206. For example, the attachment 230 can include one or more openings 232. The one or more openings 232 can use various shapes to assist in selectively distributing the coolant 212 over one or both of the coil pairs 206. In one example, each of the one or more openings 232 can define a conical shape.

[0042] Figure 8 and Figure 9 Shows another example of a portion of an inductor assembly, referred to herein as inductor assembly 250. The inductor assembly 250 can include a housing 254, a pair of coils 256, and one or more distribution ducts 258. The housing 254 and the pair of coils 256 can be sized to fit within a volume defined by a rectangular prism 259. The housing 254 can support the pair of coils 256 and define a cavity 260 sized to receive a portion of the pair of coils 256. Each of the distribution ducts 258 is horizontally oriented relative to the pair of coils 256, as Figure 8 shown. The coolant 262 can flow out of each of the distribution ducts 258 and contact a portion of one of the pair of coils 256 to assist in managing the thermal condition of the coil pair.

[0043] For example, during operation of the inductor assembly 250, the temperature of each of the coil pairs 256 can increase. Each of the connector pairs 266 can be electrically connected to one of the coil pairs 256 to deliver current to the coil pair. The coolant 262 can help cool each of the coil pairs 256 to keep the temperature within a predetermined threshold. Although the predetermined threshold can vary based on operating conditions, coolant selection, and coil type, in one example, the predetermined threshold can be between -50 degrees Celsius and 220 degrees Celsius. In another example, the predetermined threshold can be between 20 degrees Celsius and 150 degrees Celsius. Each of the distribution ducts 258 can define one or more openings for distributing the coolant 262 over each of the coil pairs 256. In one example, one or more of the openings 270 can be circular in shape. In another example, one or more of the openings 272 can be slot-shaped. Each of the distribution ducts 258 can be spaced apart from one of the coil pairs 256 by a length approximately equal to the diameter of the opening of the distribution duct 258.

[0044] Figure 10 The positional relationship of the distribution ducts 258 relative to the coil pairs 256 and the rectangular prism 259 is also shown. For example, the vehicle component 280 can limit the available packaging space adjacent to the inductor assembly 250. In this example, orienting the distribution ducts 258 horizontally relative to the coil pairs 256 provides space for the vehicle component 280. Examples of the vehicle component 280 include a portion of a transmission housing or a portion of a support fixture for an electric motor or generator. Optionally, the inductor assembly 250 can include sensors and a controller for selectively activating a coolant pump based on a received signal from the sensors, as described above.

[0045] Although various embodiments have been described above, it is not intended that these embodiments describe all possible forms covered by the appended claims. The words used in the specification are descriptive words rather than limiting words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of the various embodiments can be combined to form additional embodiments that may not be explicitly described or shown in the present invention. Although various embodiments may have been described as providing advantages or being superior to other embodiments or prior art implementations with respect to one or more desired characteristics, one of ordinary skill in the art recognizes that one or more features or characteristics may be sacrificed to achieve the desired overall system properties, depending on the particular application and implementation. These properties can include, but are not limited to, marketability, appearance, consistency, robustness, customer acceptability, reliability, accuracy, etc. Therefore, embodiments described as less satisfactory with respect to one or more characteristics than other embodiments or prior art implementations do not exceed the scope of the present disclosure and may be desirable for a particular application.

[0046] According to the present invention, there is provided a power inductor assembly having: a power inductor having a housing that supports a pair of coils; a vehicle component located above the pair of coils; and a pair of distribution ducts each oriented relative to one of the pair of coils below the vehicle component and having one or more openings adjacent to the coils to distribute coolant to the coils.

[0047] According to one embodiment, each of the one or more openings defines one of a circular shape and a slot shape.

[0048] According to one embodiment, each of the one or more openings is sized such that the exiting coolant substantially uniformly covers the adjacent coil.

[0049] According to one embodiment, each of the pair of distribution ducts is spaced from one of the pair of coils by a length approximately equal to one-half to five times the diameter of one of the one or more openings.

[0050] According to one embodiment, the vehicle component is one of a part of a transmission housing, a part of a support fixture for an electric motor or a generator, a power inductor, and a variable voltage controller housing.

[0051] According to one embodiment, the power inductor defines a rectangular prism, and each of the pair of coils is located above the rectangular prism and below the vehicle component.

[0052] According to one embodiment, the coolant is one of engine oil, transmission oil, and engine coolant.

[0053] According to the present invention, there is provided a power inductor assembly having: a power inductor including a housing that supports a pair of coils; and two distribution ducts oriented perpendicular to the coils, wherein each of the distribution ducts is arranged with one of the coils such that the coolant exiting the distribution duct covers a first predetermined area of one of the pair of coils.

[0054] According to one embodiment, the first predetermined area is further defined as an area that substantially uniformly covers one of the pair of coils.

[0055] According to one embodiment, the present invention further features: a third distribution duct spaced from one of the two distribution ducts and oriented perpendicular to one of the pair of coils for distributing coolant over the pair of coils; and a fourth distribution duct spaced from the other of the two distribution ducts and oriented perpendicular to the other of the pair of coils for distributing coolant over the pair of coils.

[0056] According to one embodiment, the present invention is further characterized by: a coolant pump fluidly connected to one of the two distribution pipes; a sensor communicating with one of the coil pairs to monitor the thermal condition of the coil pair; and a controller communicating with the sensor to receive a signal including the monitored thermal condition and communicating with the coolant pump to direct the operation of the coolant pump based on the monitored thermal condition.

[0057] According to one embodiment, the present invention is further characterized by an attachment portion sized to be mounted to an end of one of the distribution pipes, the attachment portion including a passage fluidly connected to one of the distribution pipes and one or more openings fluidly connected to the passage to disperse coolant around one of the coil pairs so as to cover a second predetermined area larger than the first predetermined area.

[0058] According to one embodiment, the present invention is further characterized by a cover sized to be mounted to an end of one of the distribution pipes, the cover including a passage configured to disperse the coolant traveling therethrough and exiting the distribution pipe.

[0059] According to one embodiment, the present invention is further characterized by a vehicle component, wherein the coil pair and the housing are sized to be located within a rectangular prism and the vehicle component is located outside the rectangular prism, and wherein the distribution pipes are arranged with the vehicle component to supply coolant to the coil pair without contacting the vehicle component.

[0060] According to the present invention, there is provided a power inductor assembly having a power inductor and an inductor thermal management system, the power inductor including a coil pair for generating energy to assist in powering a vehicle, the inductor thermal management system including a coolant circuit fluidly connected to a pair of distribution pipes, each of the pair of distribution pipes being spaced above one of the coil pairs, wherein each of the pair of distribution pipes defines an opening for delivering coolant directly onto one of the coil pairs and is spaced from the corresponding one of the coils.

[0061] According to one embodiment, each of the pair of distribution pipes is oriented perpendicular to one of the coil pairs such that each of the openings is arranged with one of the coil pairs to distribute the coolant substantially uniformly over the coil pair.

[0062] According to one embodiment, each of the pair of distribution pipes is oriented perpendicular to one of the coil pairs such that a gap is provided for a vehicle component to be located outside each of the distribution pipes and above the coil pair.

[0063] According to one embodiment, each of the pair of distribution pipes is oriented horizontally with respect to one of the coil pairs such that each of the openings is arranged with one of the coil pairs to distribute the coolant substantially uniformly over the coil pair.

[0064] According to one embodiment, each of the pair of dispensing conduits is horizontally oriented relative to one of the pair of coils to provide a space for positioning a vehicle component above the pair of dispensing conduits and a rectangular prism region defined by the power inductor.

[0065] According to one embodiment, the coolant is one of engine oil, transmission oil, and engine coolant.

Claims

1. A power inductor assembly, comprising: A power inductor having a housing that supports a pair of coils; A vehicle component located above the pair of coils; And A pair of distribution pipes for distributing coolant, each of the pair of distribution pipes being vertically oriented relative to one of the pair of coils below the vehicle component and having a first opening adjacent to the one of the pair of coils, Wherein an attachment portion is mounted at an end of each of the pair of distribution pipes, the attachment portion including one or more second openings in fluid communication with the first opening to disperse coolant around the respective one of the pair of coils.

2. The assembly according to claim 1, wherein the first opening defines one of a circular shape and a slot shape.

3. The assembly according to claim 1, wherein each of the one or more second openings defines a conical shape.

4. The assembly according to claim 1, wherein each of the pair of distribution pipes is spaced apart from one of the pair of coils by a length approximately equal to one-half to five times the diameter of the first opening.

5. The assembly according to claim 1, wherein the vehicle component is one of a part of a transmission housing, a part of a support fixture for an electric motor or a generator, the power inductor, and a variable voltage controller housing.

6. The assembly according to claim 1, wherein the power inductor defines a rectangular prism, and wherein each of the pair of coils is located above the rectangular prism and below the vehicle component.

7. The assembly according to claim 1, wherein the coolant is one of engine oil, transmission oil, and engine coolant.

8. A power inductance assembly, comprising: A power inductor having a housing that supports a pair of coils; Two distribution pipes for distributing coolant, the two distribution pipes being vertically oriented relative to the coils, wherein each of the distribution pipes is arranged with one of the coils; And An attachment portion mounted to an end of each of the two distribution pipes, the attachment portion including one or more openings in fluid communication with the respective one of the two distribution pipes to disperse coolant around the respective one of the pair of coils.

9. The assembly according to claim 8, wherein each of the one or more openings defines a conical shape.

10. The assembly according to claim 8, further comprising: A third distribution pipe spaced apart from one of the two distribution pipes and vertically oriented relative to one of the pair of coils for distributing coolant over the pair of coils; And A fourth distribution pipe spaced apart from the other of the two distribution pipes and vertically oriented relative to the other of the pair of coils for distributing coolant over the pair of coils.

11. The assembly according to claim 8, further comprising: A coolant pump in fluid communication with one of the two distribution pipes; A sensor that communicates with one of the coil pairs to monitor the thermal condition of the coil pair; and A controller that communicates with the sensor to receive a signal including the monitored thermal condition and communicates with the coolant pump to direct the operation of the coolant pump based on the monitored thermal condition.

12. The assembly of claim 8, wherein the attachment portion further includes a passage that fluidly communicates a respective one of the distribution ducts with the one or more openings.

13. The assembly of claim 8, further comprising a cap sized to be mounted to an end of one of the distribution ducts, the cap including a passage configured to disperse coolant traveling therethrough and exiting the distribution duct.

14. The assembly of claim 8, further comprising a vehicle component, wherein the coil pair and the housing are sized to be located within a rectangular prism and the vehicle component is located outside the rectangular prism, and wherein the distribution ducts are arranged with the vehicle component to supply the coolant to the coil pair without contacting the vehicle component.

15. A power inductor assembly comprising: A power inductor including a coil pair for generating energy to assist in powering a vehicle; and An inductor thermal management system including a coolant circuit fluidly communicating with a pair of distribution ducts, each of the pair of distribution ducts being spaced above and vertically oriented relative to one of the coil pairs, wherein each of the pair of distribution ducts defines a first opening for conveying coolant and is spaced from a respective one of the coil pairs, and an attachment portion is mounted at an end of each of the pair of distribution ducts, the attachment portion including one or more second openings fluidly communicating with the first opening to disperse coolant around the respective one of the coil pairs.

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