Inductive Component Liquid Cooling via Integrated Core Ducts
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Solution Overview
Problem
Current liquid cooling methods for inductive components, such as filters and transformers, are inefficient as they often result in hot spots and ineffective heat transfer, with most solutions focusing on surface heat exchangers that do not cool evenly, leading to increased component temperatures and inefficient loss transfer into cooling liquids.
Innovation Solution
The implementation of liquid cooling ducts passing through the core of inductive components and integrated liquid cooling elements within the winding, utilizing metallurgical powder structural elements with grooves for efficient heat transfer and insulation, along with optional aluminium profiles for enhanced cooling surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface heat exchangers are placed on the inductive component, then the structure is simple to manufacture, but the cooling efficiency is poor and hot spots remain
Solution Approach 1:
The cooling ducts are integrated within the core structure itself, with ducts nested inside the core's internal volume. The core is designed with hollow passages that accommodate cooling channels, allowing the cooling system to be embedded within the component rather than attached externally. This nested arrangement maximizes cooling surface area while maintaining a compact overall structure.
Solution Approach 2:
The cooling system transitions from two-dimensional surface mounting to three-dimensional internal integration. Cooling ducts are positioned at multiple levels within the core structure, including vertical and horizontal passages that extend through different sections of the core. This multi-dimensional arrangement enables heat removal from internal regions that are inaccessible to surface-mounted exchangers.
2Volume of stationary object
If surface heat exchangers are used for cooling, then the component size can be maintained, but the cooling is not even and hot spots remain
Solution Approach 1:
Different regions of the core are equipped with cooling ducts according to their specific thermal requirements. High-loss regions such as the yoke and limb sections have dedicated cooling passages positioned to match the heat generation patterns. The duct arrangement is optimized locally to address specific hot spot locations rather than using a uniform cooling approach throughout the entire core.
Solution Approach 2:
The cooling system is divided into multiple independent duct sections that can be positioned at different locations within the core. Each duct segment handles cooling for a specific region, allowing independent optimization of cooling flow rates and pathways for different thermal zones within the inductive component.
3Reliability
If liquid cooling ducts pass through the core, then heat transfer efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
Cooling ducts are pre-formed within the core structure during the core manufacturing process itself. The duct passages are created as integral parts of the core fabrication, such as through precision casting or additive manufacturing techniques that incorporate internal channels directly into the core geometry. This preliminary integration eliminates the need for separate post-manufacturing steps to install cooling ducts.
Solution Approach 2:
The core is manufactured as a composite structure combining the magnetic core material with integrated cooling channels. The ducts are formed as void spaces within the core material or as embedded conduits that are structurally integrated with the core. This composite approach allows the cooling system and core to be produced as a single unified component rather than separate assemblies.
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 approach enables efficient transfer of losses from both the core and winding into the cooling liquid, improving the overall efficiency of liquid cooling for inductive components by ensuring even cooling and reducing component temperatures.
Implementation Method 1
the loss produced in the core of the inductive component can be efficiently transferred into the cooling liquid
Implementation Method 2
liquid cooling has brought numerous advantages to power electronics, such as reduced temperatures
Data Source
AI summary
The object of the invention is a liquid cooling arrangement of an inductive component and a method for manufacturing the inductive component. The inductive component comprises at least a core (1) assembled from separate structural elements (7, 7a, 7b) as well as liquid cooling ducts (8a) integrated into the core (1) for the purpose of liquid cooling and a winding structure (3) around the core (1). The core (1) is assembled from subassemblies formed from structural elements (7, 7a, 7b), which subassemblies are separately composed of e.g. vertical pillars (35), a top horizontal beam (36) and a bottom horizontal beam (37), and cooling liquid ducts (8a) or cooling liquid pipes (10) are placed in at least a part of the subassemblies before final assembly of the core (1).