Vehicle Power Inductor Direct Coolant Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal management systems for vehicle inductors are not optimally efficient in managing heat generated by coils, relying on indirect cooling schemes with potting compounds.
Innovation Solution
A power inductor assembly with a housing supporting coils, utilizing a pair of distribution conduits oriented relative to the coils to distribute coolant directly and uniformly, with a coolant circuit in fluid communication, and a controller to manage thermal conditions based on sensor feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If indirect cooling scheme with potting compound is used, then thermal management is achieved, but cooling efficiency is reduced
Solution Approach 1:
The patent removes the potting compound intermediary from the thermal management system, extracting the direct cooling approach by allowing coolant to contact coils immediately through distribution conduits, thereby eliminating the thermal resistance layer and improving cooling efficiency
Solution Approach 2:
The patent introduces distribution conduits as new intermediaries that directly deliver coolant to coil surfaces, replacing the ineffective potting compound intermediary and enabling efficient direct liquid-to-coil thermal transfer
2Loss of energy
If distribution conduits are positioned close to coils, then cooling efficiency is improved, but space for vehicle components is reduced
Solution Approach 1:
The patent positions distribution conduits in the vertical dimension above or below coils rather than horizontally adjacent, utilizing the Z-axis space within the inductor housing to provide cooling without encroaching on horizontal space needed for vehicle component integration
3Temperature
If coolant flow is increased to improve cooling, then thermal management is enhanced, but system complexity increases
Solution Approach 1:
The patent segments the cooling system into multiple distribution conduits with individual openings positioned at specific locations around coils, allowing targeted coolant delivery to different coil regions and enabling effective cooling with moderate flow rates rather than requiring high overall flow
Solution Approach 2:
The patent creates local quality variations in coolant distribution by positioning openings at specific locations and orientations relative to coils, ensuring uniform coolant coverage where needed most while optimizing thermal management without requiring system-wide complexity increases
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 effectively manages thermal conditions by directly distributing coolant to the coils, maintaining optimal operating temperatures and reducing power losses, thereby enhancing the efficiency of the inductor assembly.
Implementation Method 1
Each of the one or more openings may be sized such that exiting coolant substantially uniformly covers the adjacent coil
Implementation Method 2
a coolant circuit in fluid communication with a pair of distribution conduits each spaced above one of the pair of coils
Data Source
AI summary
A power inductor assembly including a power inductor, a vehicle component, and a pair of distribution conduits is provided. The power inductor has a housing supporting a pair of coils. The vehicle component is located above the pair of coils. Each of the pair of distribution conduits is oriented relative to one of the pair of coils below the vehicle component and has one or more openings adjacent the coils to distribute coolant thereto. Each of the one or more openings may define one of a circular shape or a slot shape. Each of the one or more openings may be sized such that exiting coolant substantially uniformly covers the adjacent coil.