Additive Coil Component Modeling With Integrated Cooling Channels

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Solution Overview

Problem

Existing manufacturing techniques for coil-based structures result in significant material waste, design inaccuracies, and difficulty in creating complex geometries, requiring specialized tooling and fixtures, which increase setup time and cost.

Innovation Solution

A system and method utilizing a modelling platform and processing circuitry to compute and generate modelling data for fabricating components with precise conductor grooves and cooling structures, enabling thermal contact with a cooling medium, using additive manufacturing techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If existing manufacturing techniques (machining, subtractive manufacturing) are used to fabricate coil-based structures, then the structures can be produced with conventional methods, but significant material waste occurs and design precision deteriorates

Engineering Contradiction:

Improvematerial wasteVSAvoiddesign precision

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent inverts the conventional manufacturing approach by using additive manufacturing instead of subtractive manufacturing. Rather than starting with a large material stock and machining away excess material, the system builds the coil-based structure layer by layer only where material is needed, thereby eliminating material waste while achieving precise geometric configurations for optimal magnetic field distribution

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the manufacturing parameter from subtractive to additive processes. By implementing additive manufacturing techniques, the system can create complex geometries with high precision without the material removal associated with conventional machining, thus resolving the contradiction between material waste and design precision

Inventive Principle:

Principle #35Parameter changes

2Shape

If existing manufacturing systems are used to create complex geometries, then conventional tools can be employed, but design complexity increases and specialized tooling is required

Engineering Contradiction:

Improvecomplex geometriesVSAvoiddesign complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical machining systems with additive manufacturing technology. This substitution eliminates the need for specialized tooling and fixtures required for complex geometries, as the additive process can directly create intricate internal structures and conductor grooves without mechanical intervention, thereby reducing device complexity while maintaining geometric complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If existing manufacturing techniques are used for coil-based structures, then conventional processes can be applied, but setup time and cost increase due to specialized tooling and fixtures

Engineering Contradiction:

Improveease of manufactureVSAvoidsetup time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent implements self-service manufacturing through additive processes that require no specialized tooling or fixtures. The system uses digital models to directly guide the fabrication process, eliminating the need for manual setup, tooling installation, and fixture configuration, thereby reducing setup time and simplifying the manufacturing process

Inventive Principle:

Principle #25Self-service

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

Enables precise fabrication of components with uniform magnetic fields, higher cooling capabilities, and complex geometries, reducing material waste and setup costs while achieving high-performance magnetic and electrical parameters.

Implementation Method 1

The cooling structure is aligned with the set of conductors wound based on the predetermined winding pattern, thereby enabling thermal contact of the set of conductors with the cooling medium

Methodology Applied

Scientific EffectThermal contact: Conduction (thermal)

Data Source

PatentUS20260073097A1Systems, methods, and formulation for modelling components with required electrical and magnetic parameters

Publication Date: 2026.03.12 MEINKE RAINER

AI summary

Embodiments of the present disclosure disclose methods, and systems for modelling components with required electrical and magnetic parameters. The system includes a modelling platform, a processing circuitry and a modelling tool. The processing circuitry is configured to receive user inputs including modelling requirement data related to magnetic and electrical parameters of a component. The processing circuitry computes modelling parameters related to the component based on the modelling requirement data and generates modelling data based on the modelling parameters. The modelling tool is configured to access the modelling data from the processing circuitry and fabricate the component based on the modelling data. The component includes a body including a plurality of conductor grooves configured to receive a set of conductors based on a predetermined winding pattern and a cooling structure configured to receive a cooling medium.