Distributed Gap Inductor with Liquid Cooling for High Current Filtering
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Solution Overview
Problem
Existing power filtering methods and apparatuses, particularly those using inductors, face inefficiencies in terms of cost, size, and performance, especially in high current and medium voltage applications, where they struggle to effectively manage resonant points, impedance, and harmonic filtering.
Innovation Solution
The development of a distributed gap inductor apparatus with a potted or liquid-cooled system, featuring a substantially non-conductive immersion fluid and an annular core, designed for high current applications, which includes winding spacers to minimize corona potential and enhance cooling, thereby improving efficiency and reducing electromagnetic emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional inductors are used for power filtering, then basic filtering function is provided, but cost, size, and efficiency are insufficient for high current and medium voltage applications
Solution Approach 1:
The inductor core is divided into multiple segments with distributed gaps between them. This segmentation allows for better control of magnetic flux distribution, reduced core losses, and improved efficiency in high current and medium voltage applications while maintaining a manageable structure
Solution Approach 2:
The patent employs a nested structure where the core is surrounded by a first winding, which is then surrounded by a second winding. This nested arrangement optimizes space utilization, reduces overall inductor size, and improves filtering efficiency by creating multiple magnetic paths
2Volume of moving object
If inductor size is reduced for compact design, then space utilization improves, but cooling effectiveness and corona potential management become problematic
Solution Approach 1:
Winding spacers are introduced as intermediary elements between the windings and the core. These spacers provide electrical insulation to reduce corona potential, maintain proper winding spacing for effective cooling, and prevent direct contact that would cause overheating, all while fitting within a compact inductor volume
Solution Approach 2:
The patent applies different properties to different parts of the inductor structure. The winding spacers provide localized electrical insulation where corona potential is highest, while the distributed gaps in the core provide localized magnetic flux control. This targeted approach manages harmful factors without requiring overall size increase
3Loss of energy
If distributed gap core structure is implemented, then core losses and electromagnetic emissions are reduced, but manufacturing complexity increases
Solution Approach 1:
The core is segmented into multiple pieces with gaps between them, which can be manufactured separately using standard fabrication processes and then assembled. This segmentation reduces core losses and electromagnetic emissions while allowing for easier manufacturing of individual core segments compared to creating a single complex core structure
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 provides a more efficient and cost-effective power filtering system capable of handling high currents and medium voltages, with reduced core losses and electromagnetic emissions, while optimizing space and material usage.
Implementation Method 1
a substantially non-conductive immersion fluid... potted or liquid-cooled system
Implementation Method 2
liquid-cooled system... enhance cooling
Implementation Method 3
distributed gap inductor apparatus... reduced core losses
Implementation Method 4
distributed gap inductor apparatus... reduced core losses
Implementation Method 5
winding spacers to minimize corona potential
Data Source
AI summary
The invention comprises an electrical apparatus and method of manufacture. The apparatus includes a substantially annular inductor comprising an inductor core composed of at least a distributed gap material. The distributed gap material includes particles of alternating layers of magnetic and non-magnetic materials separated by a gap material. The particles comprise an average layer thickness of less than about one hundred micrometers, where a majority of said layered particles comprise an average cross sectional size of less than about one millimeter. The inductor is cooled using at least one of: a thermally conductive potting material, a liquid coolant in direct contact with the inductor, a cooling line through the potting material or liquid coolant, and a chill coil in a container about the potting material and/or the liquid coolant.