Vehicle Inductor Cooling with Integrated Zigzag Channels
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Solution Overview
Problem
The inductor in hybrid power control units of plug-in hybrid vehicles experiences performance degradation due to reduced cooling efficiency as the adhesion between the inductor and the heat radiating plate weakens over time, primarily because the grease used for indirect cooling dissipates, leading to ineffective heat dissipation.
Innovation Solution
An inductor apparatus is designed with an integrated inductor case and coolant case, featuring coolant channels formed in a zigzag shape to increase coolant residence time and enhance cooling efficiency, which maintains adhesion and prevents performance degradation by ensuring consistent cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If grease is used for indirect cooling of the inductor, then cooling is improved initially, but adhesion weakens over time causing cooling efficiency to deteriorate
Solution Approach 1:
The patent extracts the inductor from direct contact with the heat radiating plate and introduces a dedicated cooling plate structure with coolant channels. This separates the inductor mounting function from the cooling function, eliminating dependence on grease adhesion while maintaining effective cooling through direct coolant contact with the cooling plate.
Solution Approach 2:
The cooling plate acts as an intermediary component between the inductor and the cooling system. It provides a stable mounting surface for the inductor while simultaneously serving as a heat transfer medium with integrated coolant channels, replacing the grease-based thermal interface with a more reliable liquid cooling mechanism.
2Temperature
If coolant channels are formed in zigzag shape, then residence time and cooling efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the cooling plate with either the inductor case or heat radiating plate into a single integrally-formed component. This integration allows the zigzag coolant channels to be formed directly during the molding or manufacturing process of the base structure, eliminating the need for separate channel fabrication and reducing overall manufacturing complexity despite the complex channel geometry.
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
The integrated design and zigzag coolant channels improve cooling efficiency, maintaining adhesion and preventing performance degradation of the inductor, while also simplifying manufacturing and reducing costs through integral formation and efficient coolant circulation.
Implementation Method 1
a coolant case provided on a bottom surface of the inductor case, and having a coolant passage formed therein
Data Source
AI summary
An inductor apparatus for a vehicle includes an inductor boosting member configured to boost an input voltage. An inductor case has an insertion groove configured to receive the inductor boosting member inserted thereinto. An inductor cover is configured to close the inductor case. A coolant case is provided on a bottom surface of the inductor case. The coolant case has a coolant passage formed therein. A coolant cover is configured to close the coolant case.