Magnetic Core Duct Structure for Inductor Cooling and Reflow Protection
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Solution Overview
Problem
Conventional inductors with magnetic cores made of iron or ferrite suffer from energy losses due to eddy currents and hysteresis, leading to heat dissipation, and the reflow soldering process can damage electronic components if not managed properly.
Innovation Solution
An additive manufacturing process creates a magnetic component with integrated cooling channels using a ferrimagnetic material for the core and a thermally conductive, electrically insulative material for the duct, allowing for efficient heat dissipation and eliminating the need for external cooling devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional inductors use magnetic cores made of iron or ferrite to increase inductance, then magnetic field strength is improved, but energy losses due to eddy currents and hysteresis increase causing heat dissipation
Solution Approach 1:
The magnetic core is segmented into multiple magnetic segments separated by non-magnetic material regions. This segmentation interrupts eddy current paths through the core, reducing energy losses while maintaining magnetic field strength. The non-magnetic material acts as an insulator that breaks the continuous conductive path for eddy currents.
Solution Approach 2:
Different regions of the core structure are assigned different material properties: magnetic material in regions where field strength is needed, and non-magnetic material in regions where eddy current interruption is prioritized. This local differentiation optimizes both inductance and energy loss characteristics.
2Reliability
If reflow soldering is used to attach inductors to PCB, then permanent solder joints are formed, but high temperatures may damage electronic components on the printed circuit board
Solution Approach 1:
Cooling channels are pre-integrated into the inductor core structure before soldering. During the reflow soldering process, coolant flows through these channels to actively cool the inductor and surrounding PCB area, preventing thermal damage to sensitive components while allowing the solder to properly melt and form strong joints.
Solution Approach 2:
Coolant flowing through integrated channels acts as an intermediary cooling medium between the heat source (reflow soldering process) and sensitive electronic components. This intermediary system transfers heat away from critical areas, protecting components from thermal damage while maintaining soldering effectiveness.
3Loss of energy
If external cooling devices are used to dissipate heat from inductors, then heat dissipation capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The cooling function is merged with the magnetic core structure itself. Cooling channels are integrated directly into the core, eliminating the need for separate external cooling devices. This combination reduces device complexity while maintaining effective heat dissipation capability.
Solution Approach 2:
The magnetic core serves dual functions: generating magnetic field for inductance and providing structural pathways for coolant flow to enable heat dissipation. This multi-functionality eliminates the need for dedicated external cooling components, reducing overall system complexity.
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 solution provides superior cooling capabilities, reduces manufacturing costs and time, and prevents damage to components during the soldering process by integrating cooling channels within the magnetic core, enhancing the performance and reliability of inductive components.
Implementation Method 1
When the current flowing through the inductor changes, the magnetic field is generated which induces an electromotive force (i.e., a voltage) in the windings
Implementation Method 2
The magnetic core is typically formed of iron or ferrite. Due to their high magnetic permeability, such cores provide an increased magnetic field
Implementation Method 3
a duct formed of a second material extending at least partially through the body between the first inlet opening and the second outlet opening, the first inlet opening and the second outlet opening being in fluid communication by way of the duct
Data Source
AI summary
A component includes a magnetic core having a body formed of a first material, defining a first opening and a second opening thereon. A duct formed of a second material extends at least partially through the body between the first opening and the second opening. The first opening and the second opening are in fluid communication by way of the duct.