Inductor Assembly Support Structure for Transmission Cooling
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Solution Overview
Problem
Existing inductor assemblies in DC-DC converters of electric vehicles face thermal management challenges due to increased heat generation from higher current capabilities and frequency ripple currents, leading to potential temperature exceedance and reduced performance, especially when traditional cooling methods like potting compounds and external cooling systems are inefficient.
Innovation Solution
The inductor assembly is mounted within the transmission chamber, where it is directly cooled by transmission fluid, eliminating excess components like potting compounds and external housings, and supported by an insulator with spools that facilitate heat transfer and structural integrity, allowing for improved thermal performance without increasing the assembly's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling methods like potting compounds and external cooling systems are used, then the inductor assembly is protected and cooled, but the thermal resistance increases and the assembly size increases
Solution Approach 1:
The patent removes traditional cooling components such as potting compounds and external cooling systems, eliminating the thermal barrier they created. The inductor assembly is directly exposed to transmission fluid for efficient cooling without intermediary materials that increase thermal resistance.
Solution Approach 2:
The inductor assembly is integrated directly into the transmission housing, merging the cooling function with the transmission fluid circulation system. This eliminates separate cooling systems and uses the existing transmission fluid flow path to cool the inductor, reducing overall system complexity.
2Temperature
If the inductor assembly is mounted within the transmission chamber, then thermal management is improved, but the structural support and insulation requirements increase
Solution Approach 1:
The transmission housing serves multiple functions: it provides structural support for the inductor assembly, acts as an insulator between the inductor and transmission components, and facilitates cooling through fluid circulation. This multi-functional design eliminates the need for separate support and insulation components.
Solution Approach 2:
The transmission housing acts as an intermediary structure that provides both mechanical support and thermal insulation. It mediates between the high-temperature inductor assembly and the surrounding transmission components, protecting sensitive parts while maintaining cooling efficiency.
3Power
If higher current capabilities are implemented, then power output increases, but heat generation increases leading to temperature exceedance
Solution Approach 1:
The patent converts the harmful effect of increased heat generation into a benefit by using the same transmission fluid that lubricates and cools the transmission gears to also cool the inductor assembly. The heat is dissipated through the fluid circulation system already present in the transmission, turning a potential problem into an integrated solution.
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 enables effective thermal management by reducing thermal resistance and maintaining performance under high electrical loads, while minimizing size and cost impacts, and enhancing vibration resistance within the transmission environment.
Implementation Method 1
directly cooled by transmission fluid
Implementation Method 2
circulating fluid through a conduit that is proximate to the inductor
Data Source
AI summary
A vehicle is provided with a transmission and an inductor assembly that is mounted within a chamber of the transmission. The inductor assembly includes a coil, a core and an insulator having first and second portions that are oriented toward each other. Each portion includes a base, a support extending from the base, and a spool extending transversely from the support to engage the other portion. Each spool includes an external surface for supporting the coil and a cavity extending therethrough for receiving the core.