Common Mode Inductor Thermal Coupling for Ferrite Core Cooling
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Solution Overview
Problem
Existing common mode inductors in voltage converters of electric or hybrid vehicles require effective cooling solutions to manage thermal energy dissipation, as they are integral to electromagnetic compatibility filters but are not adequately addressed by current cooling methods.
Innovation Solution
A thermal coupling device comprising a prismatic ferrite core, stand, and clamping member, which transfers heat to a heat sink through a stand secured to the ferrite core, optimized by a coaxial annular structure and thermally conductive filler material, enhancing mechanical strength and thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a common mode inductor is used in an EMC filter, then electromagnetic compatibility is improved, but thermal energy dissipation increases requiring additional cooling
Solution Approach 1:
The patent combines the common mode inductor structure with a heat dissipation system by integrating the ferrite core with a heat sink through a thermally conductive stand. This merging allows the inductor to maintain its electromagnetic filtering function while simultaneously providing an efficient thermal management solution, converting the harmful thermal energy into useful heat transfer to the heat sink.
2Temperature
If cooling structures are added to the common mode inductor, then thermal management is improved, but device complexity increases
Solution Approach 1:
The stand serves multiple functions: it provides mechanical support for the ferrite core, acts as a thermal conduction path from the core to the heat sink, and contributes to the overall structural stability of the inductor assembly. This multi-functionality reduces the need for separate cooling components, thereby improving thermal management without significantly increasing device complexity.
Solution Approach 2:
The patent employs a composite structure combining ferrite material for magnetic properties with a thermally conductive material for the stand. This composite approach allows the structure to simultaneously satisfy magnetic field requirements and thermal management requirements, achieving effective cooling while maintaining structural integrity and minimizing complexity.
3Temperature
If the ferrite core is cooled through direct contact with the heat sink, then thermal transfer is improved, but mechanical stability decreases
Solution Approach 1:
The stand acts as an intermediary element between the ferrite core and the heat sink. It provides a dedicated thermal conduction path that efficiently transfers heat from the core to the heat sink while simultaneously serving as a mechanical support structure. This intermediary role allows the system to achieve both effective thermal transfer and mechanical stability without compromising either function.
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 device effectively transfers heat from the ferrite core to the heat sink, improving cooling efficiency and mechanical stability while accommodating space constraints, thus optimizing the cooling of common mode inductors.
Implementation Method 1
the ferrite core being configured to generate a magnetic field induced by an electric current flowing in the electrical connector of the electronic component
Implementation Method 2
the stand being configured to transfer the heat generated by the ferrite core to the heat sink
Data Source
AI summary
A thermal coupling device for a common mode inductor, configured to transfer heat to a heat sink. The device includes an annular prismatic ferrite core configured to be passed through by at least one electrical connector of an electronic component. A stand is secured to the heat sink, the ferrite core being in contact with the stand and the stand being configured to transfer the heat generated by the ferrite core to the heat sink. The thermal coupling device includes a clamping member configured to hold the ferrite core and the stand secured together, the ferrite core, the stand and the clamping member extending orthogonally with respect to the longitudinal reference plane of the electrical connector.