Cold Plate Inductor Cavity Thermal Management

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Solution Overview

Problem

Current thermal management systems for inductors on cold plates are inefficient in dissipating heat effectively, leading to potential temperature limitations and reduced performance of power electronic components.

Innovation Solution

A cold plate design with a machined cavity that accommodates an inductor, featuring thicker and thinner sections in the base to support the core and windings respectively, and a flow channel for coolant to enhance heat transfer, allowing for efficient heat dissipation from the inductor to the coolant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conventional cold plate design is used without a machined cavity, then the structure is simpler and easier to manufacture, but heat transfer efficiency from the inductor is reduced

Engineering Contradiction:

Improveinductor temperature controlVSAvoidcold plate structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cold plate base is segmented into thicker and thinner sections, with thicker sections positioned beneath the inductor core and thinner sections beneath the windings. This segmentation allows optimized thermal contact at different locations, improving heat transfer efficiency without requiring complete redesign of the entire cold plate structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cavity base is designed with non-uniform thickness, creating local quality variations where thicker sections provide enhanced thermal contact under the inductor core (which generates more heat) and thinner sections are sufficient under the windings. This local optimization maximizes heat transfer where needed while maintaining overall structural efficiency.

Inventive Principle:

Principle #3Local quality

2Temperature

If the cavity base has uniform thickness, then the manufacturing process is simpler, but heat transfer efficiency is reduced due to insufficient thermal contact

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidcavity base thickness variation

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The cavity base features localized thickness variations with thicker sections under the inductor core and thinner sections under the windings. This local quality approach optimizes thermal contact pressure and heat transfer efficiency at critical locations without requiring complex manufacturing processes across the entire structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The base is divided into distinct thickness zones (thicker and thinner sections) that correspond to different thermal requirements of the inductor components. This segmentation enables differentiated thermal management for the core and windings while maintaining manufacturing feasibility through integral machining.

Inventive Principle:

Principle #1Segmentation

3Temperature

If the cold plate thickness is uniform throughout, then the structure is more symmetric and easier to manufacture, but thermal management performance is reduced

Engineering Contradiction:

Improvethermal management performanceVSAvoidcold plate thickness symmetry

Core Design Contradiction:

TemperatureVSShape

Solution Approach 1:

The cold plate is designed with asymmetric thickness distribution, where the first side (containing the cavity) is thicker than the second side. This asymmetry allows the cavity base to have varied thickness sections for optimal thermal contact with the inductor, while the overall cold plate maintains structural integrity and cooling functionality.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The cold plate exhibits local quality variations in thickness to optimize thermal management performance. The thicker first side accommodates the cavity with differentiated thickness sections for maximum heat transfer, while the thinner second side maintains sufficient structural support and cooling capability.

Inventive Principle:

Principle #3Local quality

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

The solution effectively maintains the inductor's temperature below predefined limits by maximizing heat transfer from the inductor to the coolant, thereby improving the thermal management and performance of power electronic components.

Implementation Method 1

transferring heat from the components mounted on one or both surfaces to the liquid flowing within

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a flow channel formed between the first side and the second side... channel coolant into the flow channel... channel the coolant out of the flow channel

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11557419B2Thermal management of inductor on a cold plate

Publication Date: 2023.01.17 HAMILTON SUNDSTRAND CORP

AI summary

A cold plate and a method of manufacturing a cold plate involve a first side with a first surface, and a second side, opposite the first side, with a second surface opposite the first surface. The cold plate includes a flow channel formed between the first side and the second side, and a cavity integrally machined into the first surface of the first side. The cavity seats an inductor and is defined by an outer wall and a base with thicker sections and thinner sections such that even the thicker sections of the base are thinner than a thickness of the first surface.