Conductive Heat Pipe Inductor Windings for Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat management systems in electrical power systems, such as inductors and interphase transformers, are inadequate in efficiently transferring heat, leading to potential electrical component failure due to ineffective cooling methods.
Innovation Solution
The integration of a printed wiring board with electrically conductive heat pipes, where each heat pipe is u-shaped and contains a phase change material, is used to form an inductor winding, along with a housing and cold plate for enhanced thermal communication, and optionally a finned heat sink for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat management systems (fans, vents, heat sinks) are used to cool inductors, then heat can be removed from the inductor, but the system complexity and weight increase significantly
Solution Approach 1:
The patent combines the electrical winding function and heat pipe function into a single integrated structure. The heat pipes are formed directly from the conductive traces on the PCB, eliminating the need for separate cooling components. This merging of functions resolves the contradiction by providing effective heat removal without increasing system complexity.
Solution Approach 2:
The conductive traces on the PCB serve dual purposes: they provide electrical connectivity for the inductor winding and simultaneously function as heat pipes for thermal management. This multi-functionality allows the same component to address both electrical and thermal requirements, reducing overall system complexity while maintaining effective cooling.
2Temperature
If conventional heat management systems (fans, vents, heat sinks) are used to cool inductors, then heat can be removed from the inductor, but the weight of the system increases
Solution Approach 1:
By merging the electrical winding and heat pipe functions into a single integrated PCB structure, the patent eliminates the need for separate heavy cooling components such as fans, vents, and external heat sinks. The heat pipes are formed directly from the PCB traces, significantly reducing the overall weight of the cooling system while maintaining effective heat removal capability.
3Loss of energy
If conventional solid metal heat pipes are used, then heat can be conducted, but the heat transfer efficiency is limited compared to phase change materials
Solution Approach 1:
The patent utilizes phase change materials within the heat pipes to dramatically improve heat transfer efficiency. The phase transitions (evaporation and condensation) of the working fluid within the heat pipe structure enable much more effective heat transfer compared to solid metal conduction alone, resolving the contradiction by providing superior thermal performance without requiring complex active cooling systems.
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 configuration achieves superior heat transfer rates, reducing inductor winding and core temperatures, simplifying the cooling process, and reducing the complexity and weight of the cooling system compared to conventional methods, with heat transfer efficiency 2-10 times higher than conventional solid metal heat pipes.
Implementation Method 1
Each of the heat pipes in the plurality of electrically-conductive heat pipes can include a u-shaped tubular member that is electrically conductive, with a phase change material housed within the u-shaped tubular member
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An inductor includes a printed wiring board (PWB) (102) and a plurality of electrically-conductive heat pipes (104) operatively connected to the PWB. The PWB includes electrically conductive traces (106) electrically connected to the plurality of electrically-conductive heat pipes. The traces and plurality of electrically conductive heat pipes form an inductor winding. A method of manufacturing an inductor includes mounting a plurality of electrically conductive heat pipes to a printed wiring board (PWB), wherein the PWB includes electrically conductive traces to connect the plurality of electrically-conductive heat pipes to form an inductor winding.