Compact Power Inductor With Internal Coolant Flow and Closed Core
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Solution Overview
Problem
Conventional power inductors in electric vehicles face challenges with size and cooling efficiency, leading to bulkier designs and higher energy losses due to low copper utilization and inefficient external cooling methods.
Innovation Solution
A compact power inductor design featuring a closed ferromagnetic housing with access ports for coolant flow, integrating a center ferromagnetic post and coil, which forms a closed magnetic path to enhance copper utilization and reduce copper AC loss, while utilizing a hollow cuboid core and gapped portions filled with non-ferromagnetic material to manage heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional power inductors use external cooling methods, then the inductor structure is simpler to manufacture, but cooling efficiency is poor and inductor size increases
Solution Approach 1:
The patent merges the cooling function with the magnetic core structure by integrating coolant flow channels directly into the core. This combination allows the core to serve dual purposes: magnetic flux conduction and heat dissipation, thereby improving cooling efficiency while maintaining compact inductor dimensions.
Solution Approach 2:
The patent introduces coolant as an intermediary substance that flows through channels in the magnetic core to transfer heat away from the windings. This mediator enables efficient internal cooling without requiring external cooling systems, thus reducing overall inductor size while improving thermal management.
2Reliability
If conventional power inductors use more copper windings to achieve higher inductance, then inductance value increases, but copper AC loss increases and inductor size increases
Solution Approach 1:
The patent changes the magnetic path length parameter by designing a closed-loop magnetic core structure with optimized geometry. This parameter change allows achieving the required inductance value with fewer copper turns, thereby reducing copper AC losses while maintaining compact size.
Solution Approach 2:
The patent applies local quality optimization by strategically placing air gaps in specific locations of the magnetic core to control magnetic flux distribution. This localized modification improves magnetic path efficiency, allowing reduced copper usage while maintaining required inductance.
3Ease of manufacture
If conventional power inductors use open magnetic core structures, then manufacturing is easier, but copper utilization is low and inductor size increases
Solution Approach 1:
The patent merges the magnetic core structure with the cooling system by integrating coolant channels directly into the core. This unified structure achieves compact inductor size while maintaining manufacturing feasibility through standardized core formation processes.
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 proposed design achieves higher inductance with fewer turns and less copper, reducing energy losses and inductor size, while improving cooling efficiency by directly contacting the windings with coolant, thus addressing the inefficiencies of conventional inductors.
Implementation Method 1
the access ports are configured to permit flow of coolant into the closed ferromagnetic housing and around the center ferromagnetic post to cool the at least one conductor
Implementation Method 2
at least one conductor, contained within and completely surrounded by the closed ferromagnetic housing, wound around the center ferromagnetic post such that the closed ferromagnetic housing, center ferromagnetic post, and at least one conductor form an inductor
Data Source
AI summary
A closed ferromagnetic housing has a pair of access ports and a center ferromagnetic post extending from and between opposite ends thereof. At least one conductor, contained within and completely surrounded by the closed ferromagnetic housing, is wound around the center ferromagnetic post such that the closed ferromagnetic housing, center ferromagnetic post, and at least one conductor form an inductor in which the ferromagnetic housing and the center ferromagnetic post define a core of the inductor and the at least one conductor defines a coil of the inductor. The access ports are configured to permit flow of coolant into the closed ferromagnetic housing and around the center ferromagnetic post to cool the at least one conductor.