Immersion-Cooled Inductor Coils for Compact High-Power DC-DC Converters
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Solution Overview
Problem
High-power DC-DC converters face challenges in efficient cooling, particularly in small form factors, where heat dissipation is significant, and thermal coupling with heat-generating components is difficult, leading to performance degradation and potential damage from temperature fluctuations.
Innovation Solution
The implementation of immersion-cooling features, such as grooved metal sheets in inductor coil assemblies for direct liquid contact, combined with conductive and convective cooling methods, allows for efficient heat management in high-power applications, enabling operation at high power densities without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If passive cooling (heat sinks) or active cooling (fans, liquid cooling) components are integrated into DC-DC converters, then cooling capability is improved, but device volume increases significantly
Solution Approach 1:
The cooling channels are merged directly into the inductor core structure, combining the magnetic core and cooling functions into a single integrated component. This eliminates the need for separate cooling components and reduces overall device volume while maintaining effective heat dissipation capability
Solution Approach 2:
The inductor core serves dual functions: magnetic flux conduction and heat dissipation. By incorporating cooling channels within the core structure, the same component performs both electromagnetic and thermal management functions, reducing the need for additional dedicated cooling components
2Temperature
If cooling components are added to DC-DC converters, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The cooling system is merged with the inductor assembly, using the existing magnetic core structure to house the cooling channels. This integration simplifies the overall system by eliminating separate cooling components and reducing the number of assembly steps
Solution Approach 2:
The inductor core itself serves as the heat dissipation structure, with cooling channels formed directly within it. The core material and geometry are designed to facilitate heat transfer from the windings to the cooling fluid, making the inductor self-sufficient for thermal management
3Temperature
If thermal coupling with heat-generating components is established, then cooling effectiveness is improved, but manufacturing difficulty increases
Solution Approach 1:
The cooling channels are formed within the inductor core during the core manufacturing process, before the windings are assembled. This preliminary integration of cooling features into the core structure simplifies subsequent assembly steps and ensures optimal thermal coupling from the start
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 solution enables DC-DC converters to operate efficiently at high power levels (up to 200 kW) with compact designs, maintaining performance and preventing component damage through effective thermal management, achieving power-to-volume ratios of at least 2 kW per liter.
Implementation Method 1
An inductor-cooling liquid may be pumped through these fluid pathways while being in direct contact with the metal sheet, at least around the grooves
Implementation Method 2
An inductor-cooling liquid may be pumped through these fluid pathways while being in direct contact with the metal sheet
Data Source
AI summary
Described herein are DC-DC converters having various immersion-cooling features enabling high-power applications, such as cross-charging electric vehicles. For example, the inductor of a DC-DC converter may be formed using metal and insulator sheets stacked and wound into an inductor coil assembly. The metal sheet comprises grooves, extending parallel to the coil axis and forming coil fluid pathways through this assembly thereby providing immersion cooling to the inductor. An inductor-cooling liquid may be pumped through these fluid pathways while being in direct contact with the metal sheet, at least around the grooves. In some examples, these grooves are distributed along the entire length of the metal sheet. Multiple inductors may be used to enable operations of multiple converter units, e.g., operating out of phase. These inductors may be fluidically interconnectors and have the same cooling features.