Actively Cooled Inductor With Sealed Bobbin Flow Channels
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Solution Overview
Problem
Inductors in electric drive systems generate significant heat due to the variable voltage converter, which is not efficiently managed by existing cooling methods, limiting their performance and reliability.
Innovation Solution
An actively cooled inductor design featuring a magnetically conductive core, electrically conductive windings, and a bobbin with spiral locating features, where a plastic filler is injected to exert radial pressure and seal the winding, allowing for fluid cooling through inlet and outlet ports to effectively dissipate heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used for inductors, then the structure is simple, but heat dissipation efficiency is insufficient
Solution Approach 1:
The patent merges the cooling function directly into the inductor structure by integrating cooling channels within the bobbin and windings, combining the magnetic component with the thermal management system into a single integrated unit, thereby improving heat dissipation efficiency while avoiding the complexity of separate cooling systems
Solution Approach 2:
The patent introduces a cooling fluid as an intermediary substance that flows through the integrated channels to transfer heat away from the inductor windings and core, enabling efficient heat dissipation through fluid-mediated thermal transfer rather than relying on passive conduction alone
2Reliability
If plastic filler is injected to seal the winding, then thermal management is improved, but manufacturing complexity increases
Solution Approach 1:
The plastic filler material serves multiple functions simultaneously: it seals the winding against the bobbin to prevent fluid leakage, provides structural support, and acts as a thermal pathway. This self-service approach consolidates multiple functions into a single material, improving thermal management reliability while minimizing the need for additional manufacturing steps
Solution Approach 2:
The patent uses plastic filler as a composite material that combines sealing, structural, and thermal management properties in one substance, eliminating the need for separate sealing components and simplifying the overall manufacturing process while enhancing thermal management reliability
3Reliability
If the winding is partially embedded into the bobbin, then sealing is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical state and properties of the plastic filler material during the injection process, using its flow characteristics to automatically conform to the bobbin and winding interface. This parameter-based approach allows the filler to self-adjust and seal gaps without requiring high-precision embedding, improving sealing effectiveness while reducing manufacturing precision requirements
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 actively cooled inductor design significantly enhances heat dissipation, improving the reliability and performance of electric drive systems by efficiently managing thermal issues within the inductor components.
Implementation Method 1
The plastic filler may exert radial pressure on the bobbin such that the winding is partially embedded into the bobbin to seal the winding against the bobbin
Implementation Method 2
The inlet port is configured to direct fluid through the channel to cool the inductor
Implementation Method 3
The actively cooled inductor design significantly enhances heat dissipation, improving the reliability and performance of electric drive systems
Implementation Method 4
The core is magnetically conductive
Implementation Method 5
During operation, an inductor associated with the variable voltage may generate heat
Data Source
AI summary
An electric drive system includes an actively cooled inductor. The inductor is formed by winding C-shaped wire around a bobbin such that channels are defined between the bobbin and the wire. After the bobbin is installed over the core, a plastic layer is injected between the core and the bobbin. This expands the bobbin against the wire to seal the channels and also to fasten the bobbin in place. A variety of porting arrangements are proposed to route cooling fluid through the channels to cool the windings and the core.