Inductive Component Thermal Management via Conductive Insulator Jacket
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Solution Overview
Problem
Existing inductive components face challenges in achieving efficient heat dissipation, particularly with cylindrical windings on magnetic cores, as conventional cooling methods do not effectively utilize the surface area for thermal contact, leading to suboptimal cooling capacity and increased installation space.
Innovation Solution
The design features a heat-conducting insulator that fits along the axial surface of the winding, forming a jacket that encloses the winding and is matched to the housing's interior contour, creating a large thermal contact surface, with options including tubular heat pipes or heat-conducting films, and additional features like cooling fins and compression for enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a flat cooling element with a heat-conducting foil is used for cooling, then thermal contact is achieved, but the thermal contact surface area is limited and cooling efficiency is insufficient
Solution Approach 1:
The patent applies a cylindrical insulator instead of a flat cooling element to match the cylindrical geometry of the winding. This curved surface configuration enables the insulator to wrap around and contact the entire outer surface of the cylindrical winding, significantly increasing the thermal contact surface area compared to flat cooling elements.
Solution Approach 2:
The insulator is positioned between the winding and the housing, creating a nested arrangement where the insulator is enclosed by the housing while simultaneously enclosing the winding. This nested structure allows the insulator to maximize thermal contact with the winding surface while being contained within the housing boundaries.
2Temperature
If the thermal contact surface area is increased, then cooling capacity improves, but the installation space increases
Solution Approach 1:
The insulator serves multiple functions simultaneously: it provides electrical insulation between the winding and housing, acts as a thermal conduction path from the winding to the housing, and functions as a structural component that fits within the housing. This multi-functionality allows the insulator to contribute to cooling efficiency without requiring additional dedicated cooling components that would increase installation space.
Solution Approach 2:
The patent combines the insulation function and thermal conduction function into a single integrated insulator component. By making the insulator itself thermally conductive, the design eliminates the need for separate insulation and cooling components, thereby achieving high cooling capacity within limited installation space.
3Temperature
If conventional cooling methods are used, then the structure is simple, but heat dissipation efficiency is insufficient
Solution Approach 1:
The patent changes the thermal conduction parameter by using a thermally conductive insulator material instead of conventional electrical insulation materials with low thermal conductivity. This parameter change enables the insulator to effectively transfer heat from the winding to the housing, significantly improving heat dissipation efficiency without adding complex cooling mechanisms.
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 significantly improves heat dissipation capacity while minimizing installation space, achieving high cooling efficiency through increased thermal contact and effective heat transfer resistance reduction.
Implementation Method 1
the winding being heat-coupled to a cooling element via a heat-conducting insulator
Implementation Method 2
the insulator is tubular, in particular in the form of a heat pipe, as a result of which a high heat flow from the winding into the housing is achieved via this heat pipe
Data Source
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AI summary
An inductive component (1) with at least one winding (2.1, 2.2), wherein the winding (2.1, 2.2) is thermally coupled to a cooling element (3) via a thermally conductive insulator (4.1, 4.2). According to the invention, the insulator (4.1, 4.2) is designed as a sheath that at least partially surrounds the at least one winding (2.1, 2.2) in a surface-locking manner, and the cooling element is designed as a housing (3) accommodating the at least one winding (2.1, 2.2) with an interior space (3.11, 3.12, 3.21, 3.22), wherein the inner contour of the interior space (3.11, 3.12, 3.21, 3.22) of the housing (3) is adapted to the outer contour of the insulator (4.1, 4.2).