A water-cooled heat dissipation coupled inductor

Abstract

This utility model relates to a water-cooled heat dissipation coupled inductor in the field of inductors, including an inductor body and a protective shell. The protective shell is equipped with a water-cooling assembly, which consists of a water-cooling plate, a heat exchanger, water pipes, and a water pump. The water-cooling plate has a cooling water circuit, and the heat exchanger has a heat exchange water circuit. The water-cooling plate, the heat exchanger, and the water pump are connected by water pipes filled with coolant. The coolant circulates between the water-cooling plate and the heat exchanger through the water pump. The water-cooling plate includes a fixed base plate and a positioning vertical plate. The fixed base plate is fixedly installed on the inner wall of the protective shell. The positioning vertical plate is vertically set in the middle of the fixed base plate. The end of the positioning vertical plate away from the fixed base plate is provided with a positioning groove that matches and engages with the inductor body. The inner wall of the positioning groove fits against the inductor body. The side and bottom surfaces of the inductor body can fit tightly against the inner wall of the positioning groove of the water-cooling plate, which greatly increases the effective contact area between the water-cooling plate and the inductor body.

Description

Technical Field

[0001] This utility model relates to the field of inductors, and in particular to a water-cooled heat dissipation coupled inductor. Background Technology

[0002] With the rapid development of power electronics technology, high-frequency, high-power power electronic equipment, such as new energy vehicle charging piles, photovoltaic inverters, and energy storage converters, places increasingly stringent requirements on the performance and reliability of core power devices. As a key energy storage and filtering component in such equipment, the coupled inductor generates a significant amount of heat during operation due to core losses and winding copper losses. Especially with the trend towards higher power density and higher frequency, the heat generation per unit volume of the inductor increases dramatically, and its heat dissipation performance directly affects the overall efficiency, power density, long-term operational stability, and service life of the equipment.

[0003] Currently, there are two main types of coupled inductor heat dissipation solutions used in the above scenarios:

[0004] 1. Air cooling or natural heat dissipation: Most solutions rely on the inductor's own surface area for heat dissipation or use system fans for forced airflow convection. This method has relatively low heat dissipation efficiency, especially in enclosed or space-constrained equipment. More seriously, after prolonged operation, dust can easily accumulate on the inductor surface or block airflow channels, leading to a sharp decline in heat dissipation efficiency. The inductor is prone to reaching thermal saturation, resulting in uncontrolled temperature rise, performance degradation, or even burnout.

[0005] 2. Water Cooling: A few solutions attempt to incorporate water cooling, typically by simply attaching the inductor body to the surface of a flat water-cooling plate. However, this planar contact method has a very limited contact area, and there is significant contact thermal resistance between the inductor body and the water-cooling plate, greatly reducing heat transfer efficiency and making it difficult to meet the high heat dissipation requirements of high-frequency, high-power inductors. Furthermore, unavoidable vibrations during equipment operation or transportation can easily cause the inductor body to detach or lose contact with the flat water-cooling plate. Once detached, not only will overall heat dissipation fail, but severe localized overheating hotspots will also occur, causing irreversible damage to the inductor and posing a serious challenge to system reliability. Utility Model Content

[0006] In order to overcome the shortcomings of existing technical solutions, this utility model provides a water-cooled heat dissipation coupled inductor, which can effectively solve the technical problems of low reliability and insufficient efficiency of water-cooled heat dissipation.

[0007] The technical solution adopted by this utility model to solve its technical problem is:

[0008] A water-cooled coupled inductor includes an inductor body and a protective shell. The protective shell has a cavity within which the inductor body is fixedly installed. The leads of the inductor body pass through the protective shell. A water-cooling assembly is installed on the protective shell. The water-cooling assembly consists of a water-cooling plate, a heat exchanger, water pipes, and a water pump. The water-cooling plate has cooling water channels, and the heat exchanger has hot water channels. The water-cooling plate, heat exchanger, and water pump are connected by water pipes filled with coolant. The coolant circulates between the water-cooling plate and the heat exchanger via the water pump. The water pump and heat exchanger are installed on the outside of the protective shell. The water-cooling plate has a T-shaped cross-section and includes a fixed base plate and a positioning vertical plate. The fixed base plate is fixedly installed to the inner wall of the protective shell. The positioning vertical plate is vertically positioned in the middle of the fixed base plate. A positioning groove is provided at the end of the positioning vertical plate away from the fixed base plate, which engages with the inductor body. The inner wall of the positioning groove is in contact with the inductor body.

[0009] Furthermore, the bottom surface of the positioning groove contacts the inductor body through a thermally conductive silicone pad, and a thermally conductive silicone pad is provided on the side wall of the positioning groove, which is attached to the side wall of the inductor body.

[0010] Furthermore, a fixed cover plate is connected to the end of the positioning vertical plate away from the fixed base plate, and the fixed cover plate covers the opening of the positioning groove.

[0011] Furthermore, the protective housing consists of a bottom shell and a top cover, with the receiving cavity located inside the bottom shell and its opening facing upwards, and the top cover used to cover the receiving cavity.

[0012] Furthermore, the fixed base plate is installed on the inner wall of the top cover, the water pump and heat exchanger are installed on the outer wall of the top cover, and the middle section of the water pipe passes through the top cover.

[0013] Furthermore, the pins of the inductor body pass through the bottom case and extend below the bottom case.

[0014] Furthermore, a cooling fan is detachably mounted on the side wall of the heat exchanger.

[0015] Furthermore, the inductor body is composed of a magnetic core and a coil, with the coil wound around the surface of the magnetic core and the magnetic core engaging with the positioning groove.

[0016] Compared with existing technologies, the advantages of this invention are as follows: the positioning plate extends vertically into the inductor mounting area and has a positioning groove at its end that precisely matches and engages with the inductor body. This three-dimensional encapsulation structure allows the sides and bottom of the inductor body to fit tightly against the inner wall of the positioning groove of the water-cooling plate, greatly increasing the effective contact area between the water-cooling plate and the inductor body. The increased contact area directly reduces the contact thermal resistance and significantly improves the efficiency of heat transfer from the inductor body to the coolant. The positioning groove design not only increases the contact area but also plays a crucial role in mechanical positioning and engagement. The inductor body is firmly engaged in the positioning groove, ensuring that the two maintain a tight and stable contact even when subjected to vibration during equipment operation or transportation. Attached Figure Description

[0017] Figure 1 This is a top view of the structure of this utility model;

[0018] Figure 2 This is the main view of the present invention.

[0019] Figure 3 This is a diagram showing the connection structure between the water-cooled plate and the water-cooled plate in this utility model;

[0020] The numbers in the diagram are: 1-Inductor body, 2-Receiving cavity, 3-Protective shell, 301-Bottom shell, 302-Top cover, 4-Water cooling plate, 401-Fixing base plate, 402-Positioning vertical plate, 403-Positioning groove, 404-Fixing cover plate, 5-Heat exchanger, 6-Water pump, 7-Cooling fan, 8-Thermal conductive silicone pad, 9-Thermal conductive silicone mat. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] The following is combined Figures 1-3 A detailed description of a water-cooled heat dissipation coupled inductor according to this utility model is provided:

[0023] A water-cooled coupling inductor includes an inductor body 1 and a protective shell 3. A receiving cavity 2 is provided inside the protective shell 3. The inductor body 1 is fixedly installed inside the receiving cavity 2, and the leads of the inductor body 1 pass through the protective shell 3. The inductor body 1 is composed of a magnetic core and a coil, with the coil wound around the surface of the magnetic core. The magnetic core engages with a positioning groove 403. A water-cooling assembly is installed on the protective shell 3. The water-cooling assembly includes a water-cooling plate 4, a heat exchanger 5, water pipes, and a water pump 6. Cooling water channels are provided inside the water-cooling plate 4, and heat exchanger channels are provided inside the heat exchanger 5. The water-cooling plate 4, heat exchanger 5, and water pump 6 are connected by... Water pipes are connected and filled with coolant. The coolant circulates between the water-cooled plate 4 and the heat exchanger 5 via a water pump 6. The water pump 6 and the heat exchanger 5 are installed on the outside of the protective shell 3. The water-cooled plate 4 has a "T" shaped cross section and includes a fixed base plate 401 and a positioning vertical plate 402. The fixed base plate 401 is fixedly installed on the inner wall of the protective shell 3. The positioning vertical plate 402 is vertically set in the middle of the fixed base plate 401. The end of the positioning vertical plate 402 away from the fixed base plate 401 is provided with a positioning groove 403 that matches and engages with the inductor body 1. The inner wall of the positioning groove 403 is in contact with the inductor body 1.

[0024] Compared to traditional natural or air cooling methods, this solution employs an active water-cooling circulation system. Utilizing the high specific heat capacity and forced circulation of the coolant, it can quickly and efficiently remove the heat generated by the inductor from its source, significantly improving heat dissipation efficiency. This fundamentally solves the heat dissipation problem of high-frequency, high-power inductors in high-power-density devices, significantly reduces the inductor's operating temperature, and effectively avoids heat saturation problems caused by dust accumulation blocking the airflow.

[0025] The positioning plate 402 extends vertically into the inductor mounting area and has a positioning groove 403 at its end that precisely matches and engages with the inductor body 1. This three-dimensional encapsulation structure allows the sides and bottom of the inductor body 1 to fit tightly against the inner wall of the positioning groove 403 of the water-cooling plate 4, greatly increasing the effective contact area between the water-cooling plate 4 and the inductor body 1. The increased contact area directly reduces the contact thermal resistance and significantly improves the efficiency of heat transfer from the inductor body 1 to the coolant. The design of the positioning groove 403 not only increases the contact area but also plays a crucial role in mechanical positioning and engagement. The inductor body 1 is firmly engaged within the positioning groove 403, ensuring that the two maintain a tight and stable contact even when subjected to vibration during equipment operation or transportation.

[0026] The bottom surface of the positioning groove 403 contacts the inductor body 1 through a thermally conductive silicone sheet 8. A thermally conductive silicone pad 9 is provided on the side wall of the positioning groove 403. The thermally conductive silicone pad 9 fits against the side wall of the inductor body 1. The thermally conductive silicone pad 9 and the thermally conductive silicone sheet 8 further eliminate contact gaps and maximize heat conduction efficiency. The thermally conductive silicone material can perfectly fill the microscopic gap between the magnetic core and the metal inner wall of the positioning groove 403, significantly reducing or even eliminating contact thermal resistance, ensuring that heat is transferred to the cooling water channel of the water-cooled plate 4 without obstruction. The elastic properties of the silicone material provide excellent shock absorption and buffering effect, effectively absorbing the vibration energy during equipment operation or transportation, preventing small displacements or wear caused by hard contact, further consolidating the tight fit, ensuring long-term reliability of the heat dissipation channel, and forming a flexible wrap on the surface of the magnetic core to avoid mechanical damage caused by direct contact with hard metal, and can adapt to certain manufacturing tolerances.

[0027] The end of the positioning vertical plate 402 away from the fixed base plate 401 is connected to a fixed cover plate 404. The fixed cover plate 404 covers the opening of the positioning groove 403. Based on the engagement of the positioning groove 403, axial constraint is added, which completely eliminates the possibility of the inductor body 1 coming out of the positioning groove 403 under strong vibration or impact. The safety meets industrial-grade requirements. The cover plate can apply a moderate clamping force to optimize the contact pressure distribution and ensure that the thermally conductive silicone sheet 8 and the thermally conductive silicone pad 9 are subjected to uniform force on the entire contact surface, thereby improving the integrity and efficiency of the thermal interface.

[0028] The protective housing 3 consists of a bottom shell 301 and a top cover 302. The receiving cavity 2 is located inside the bottom shell 301 with its opening facing upwards. The top cover 302 is used to cover the receiving cavity 2. The split structure greatly simplifies the process of installing the inductor body 1, positioning the water cooling plate 4, arranging the pins, and performing subsequent maintenance, realizing modular disassembly and assembly. The pins of the inductor body 1 pass through the bottom shell 301 and extend to the bottom of the bottom shell 301.

[0029] The fixed base plate 401 is installed on the inner wall of the top cover 302, the water pump 6 and the heat exchanger 5 are installed on the outer wall of the top cover 302, and the middle section of the water pipe passes through the top cover 302. The core heat dissipation component water cooling plate 4 and the external circulation component pump and heat exchanger 5 are integrated on the top cover 302 unit to form a compact "heat dissipation top cover 302" module, which greatly saves the internal space of the equipment and optimizes the overall layout.

[0030] The heat exchanger 5 is detachably equipped with a cooling fan 7 on its side wall. Under high ambient temperature or extreme load conditions, the fan can force convection, significantly improving the heat dissipation efficiency of the heat exchanger 5, ensuring stable coolant temperature, and making the system more capable of handling peak power.

[0031] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A water-cooled heat dissipation coupled inductor, comprising an inductor body and a protective housing, wherein a receiving cavity is provided inside the protective housing, the inductor body is fixedly installed inside the receiving cavity, and the leads of the inductor body pass through the protective housing, characterized in that: The protective housing is equipped with a water-cooling assembly, which consists of a water-cooling plate, a heat exchanger, water pipes, and a water pump. The water-cooling plate has a cooling water circuit, and the heat exchanger has a heat exchange water circuit. The water-cooling plate, heat exchanger, and water pump are connected by water pipes filled with coolant. The coolant circulates between the water-cooling plate and the heat exchanger through the water pump. The water pump and heat exchanger are installed on the outside of the protective housing. The water-cooling plate has a "T" shaped cross-section and includes a fixed base plate and a positioning vertical plate. The fixed base plate is fixedly installed on the inner wall of the protective housing. The positioning vertical plate is vertically set in the middle of the fixed base plate. The end of the positioning vertical plate away from the fixed base plate is provided with a positioning groove that matches and engages with the inductor body. The inner wall of the positioning groove is in contact with the inductor body.

2. The water-cooled heat dissipation coupled inductor according to claim 1, characterized in that: The bottom surface of the positioning groove is in contact with the inductor body through a thermally conductive silicone pad, and a thermally conductive silicone pad is provided on the side wall of the positioning groove, which is attached to the side wall of the inductor body.

3. The water-cooled heat dissipation coupled inductor according to claim 1, characterized in that: The end of the positioning vertical plate away from the fixed base plate is connected to a fixed cover plate, which covers the opening of the positioning groove.

4. A water-cooled heat dissipation coupled inductor according to any one of claims 1-3, characterized in that: The protective shell consists of a bottom shell and a top cover. The receiving cavity is located inside the bottom shell with its opening facing upwards, and the top cover is used to cover the receiving cavity.

5. A water-cooled heat dissipation coupled inductor according to claim 4, characterized in that: The fixed base plate is installed on the inner wall of the top cover, the water pump and heat exchanger are installed on the outer wall of the top cover, and the middle section of the water pipe passes through the top cover.

6. The water-cooled heat dissipation coupled inductor according to claim 4, characterized in that: The pins of the inductor body pass through the bottom case and extend below the bottom case.

7. A water-cooled heat dissipation coupled inductor according to any one of claims 1-3, characterized in that: A cooling fan is detachably mounted on the side wall of the heat exchanger.

8. A water-cooled heat dissipation coupled inductor according to any one of claims 1-3, characterized in that: The inductor body is composed of a magnetic core and a coil, with the coil wound around the surface of the magnetic core and the magnetic core engaging with the positioning groove.

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