Inductor Cooling Element with Biasing Mechanism for Thermal Contact
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Solution Overview
Problem
Power electronic devices, such as inductors, experience heat buildup due to coil and core losses, leading to reduced performance and potential failure, as existing cooling systems are inadequate in managing thermal energy effectively.
Innovation Solution
A biasing element is used to urge a cooling element into close thermal contact with both the magnetic core and conductive coil of an inductor, reducing thermal resistance and enhancing heat transfer through the use of a cooling fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a cooling element is used to remove heat from the inductor, then heat transfer efficiency is improved, but thermal resistance at the interface between components remains high
Solution Approach 1:
The biasing element is pre-installed between the core pieces to automatically urge the cooling element into close thermal contact with both the magnetic core and conductive coil when the inductor is assembled. This preliminary action ensures optimal thermal contact is established before operation, reducing thermal resistance at the interfaces without requiring additional adjustment mechanisms.
Solution Approach 2:
The biasing element acts as an intermediary component that transmits mechanical force from the core pieces to the cooling element. This mediator ensures continuous pressure is applied to maintain intimate thermal contact between the cooling element and the heat-generating components, thereby reducing thermal resistance while allowing for thermal expansion during operation.
2Productivity
If the inductor operates at high power, then productivity is improved, but heat buildup increases causing performance degradation
Solution Approach 1:
The invention converts the harmful effect of heat buildup into a beneficial self-regulating mechanism. The biasing element is designed to allow the core pieces to expand thermally during high-power operation while maintaining or even increasing the urging force on the cooling element. Thus, the thermal energy that would normally degrade performance is instead used to enhance thermal contact and improve heat removal efficiency.
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 effectively reduces thermal resistance and improves heat transfer from the inductor components, thereby enhancing the cooling efficiency and extending the lifespan of power electronic devices by managing thermal energy more effectively.
Implementation Method 1
The contact may close this and reduce the thermal resistance at the interfaces of the components, and thus promote heat transfer from the magnetic core and the conductive coil to the cooling element
Implementation Method 2
The cooling element is configured to extract the heat from the inductor, such as via the flow of a cooling fluid
Implementation Method 3
The biasing element provides a biasing force to urge at least one cooling element disposed within the inductor into contact with a coil, and, where desired, into good thermal contact with both the core and the coil
Data Source
AI summary
Provided is an electrical apparatus comprising a magnetic core, a conductive coil wound around at least a part of the core, a cooling element configured to receive a cooling fluid to cool the core and the coil during operation, and at least one biasing element operatively associated with the core to urge the core and the coil into engagement with the cooling element despite differential expansion or contraction of the core and the coil and manufacturing tolerances. Further provided is a method for making an electrical apparatus comprising disposing a conductive coil wound around at least a part of a magnetic core, disposing a cooling element between the core and the coil, the cooling element configured to receive a cooling fluid to cool the core and the coil during operation, and urging the core and the coil into engagement with the cooling element despite differential expansion or contraction of the core and the coil and manufacturing tolerances.