Assembled Inductor Gaps for Fluid-Cooled Heat Dissipation
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Solution Overview
Problem
Conventional inductors lack an efficient mechanism for heat dissipation using a fluid medium, such as air or liquid coolant, which limits their thermal management capabilities.
Innovation Solution
The assembled inductor design incorporates a first and second magnetic core, along with a metal member between them, featuring a plurality of gaps that allow a fluid medium to pass through, enhancing heat transfer performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional inductor design with solid structure is used, then manufacturing simplicity is maintained, but heat dissipation capability deteriorates
Solution Approach 1:
The inductor core is designed with a porous structure containing multiple through-holes that allow fluid medium to flow through. This porous configuration enables efficient heat dissipation by facilitating direct contact between the cooling fluid and the heat-generating components, while maintaining structural integrity through the careful design of hole distribution and dimensions.
Solution Approach 2:
The core structure is segmented into multiple sections with through-holes distributed throughout. This segmentation creates multiple flow paths for the fluid medium, increasing the surface area for heat exchange and improving overall heat dissipation efficiency without requiring a complete redesign of the inductor architecture.
2Temperature
If fluid medium flow paths are added to inductor, then heat transfer performance is improved, but manufacturing complexity increases
Solution Approach 1:
The porous core structure is designed to be compatible with conventional manufacturing processes. The through-holes are integrated into the core formation process, allowing fluid channels to be created during core manufacturing rather than requiring additional post-processing steps. This approach maintains manufacturing simplicity while enabling effective fluid flow for heat dissipation.
3Temperature
If gaps are formed among magnetic cores and metal member, then heat dissipation is enhanced, but structural integrity may be compromised
Solution Approach 1:
The gaps between magnetic cores and metal members are strategically designed to create fluid flow channels while maintaining overall structural integrity. The segmentation is performed in a way that preserves the mechanical strength of individual components and their mounting structures, ensuring that the inductor maintains its structural stability during operation despite the presence of multiple gaps.
Solution Approach 2:
The fluid medium acts as an intermediary that passes through the gaps between components. These gaps are designed to allow fluid flow while the surrounding structural elements maintain the mechanical integrity of the assembly. The gaps serve dual purposes: enabling heat dissipation and maintaining component positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively increases heat transfer performance by allowing a fluid medium to flow through the gaps, thereby improving the thermal management of inductors.
Implementation Method 1
a plurality of gaps formed among the first magnetic core, the second magnetic, and the metal member... allowing a fluid medium (e.g., air or a liquid coolant) to pass through, thereby increasing heat transfer performance
Implementation Method 2
allowing a fluid medium to pass through, thereby increasing heat transfer performance... effectively increases heat transfer performance by allowing a fluid medium to flow through the gaps
Data Source
AI summary
An assembled inductor includes a first magnetic core; a second magnetic core; a metal member disposed between the first magnetic core and the second metal member; and a plurality of gaps formed among the first magnetic core, the second magnetic, and the metal member. Further, the first magnetic core includes a plurality of inner projections. Furthermore, there is provided a second metal member disposed in the metal member.