Inductor Module Thermal Frame for Heat Dissipation Without Corrosion
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Solution Overview
Problem
Existing inductor designs face challenges in heat dissipation, particularly in high-power applications, where metal conduction methods can lead to rust and corrosion, compromising component efficiency and operation.
Innovation Solution
The inductor module incorporates a thermal conductive frame with a magnetic material that covers internal conductors, using high thermal conductivity materials like copper, silver, or aluminum nitride, and includes a connecting bar to facilitate heat transfer, with optional openings for better heat dissipation through thermal interface materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal conduction is used to dissipate heat from the inductor, then heat dissipation efficiency is improved, but the metal components are susceptible to rust and corrosion in humid environments
Solution Approach 1:
The patent introduces a thermal conductive frame as an intermediary component between the internal conductor and the external environment. This frame is made of corrosion-resistant material that can conduct heat effectively while being protected from direct exposure to corrosive environments, thus mediating between the heat dissipation requirement and the corrosion resistance requirement
Solution Approach 2:
The patent employs composite material structure where the thermal conductive frame combines high thermal conductivity with corrosion resistance properties. By using materials that possess both characteristics or by creating a composite structure, the system achieves effective heat dissipation while maintaining reliability in humid environments
2Temperature
If the thermal conductive frame is exposed to the environment for heat dissipation, then heat transfer efficiency is improved, but the frame becomes vulnerable to rust and corrosion
Solution Approach 1:
The patent creates a protected environment for the thermal conductive frame by enclosing it within the magnetic material shell. This forms an inert or controlled atmosphere inside the inductor module that prevents corrosive elements from reaching the thermal conductive frame, while the frame continues to perform its heat transfer function effectively
3Reliability
If corrosion-resistant materials are used for the thermal conductive frame, then reliability is improved, but thermal conductivity may be reduced compared to highly conductive metals
Solution Approach 1:
The patent resolves this contradiction by using composite materials or material combinations that achieve both corrosion resistance and high thermal conductivity. The thermal conductive frame may use materials like aluminum alloys or coated metals that balance these two properties, or employ a composite structure where different materials work together to provide both protection and heat conduction
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 effectively dissipates heat while preventing corrosion, enhancing the inductor's performance and reliability by ensuring the thermal conductive frame is protected from air exposure.
Implementation Method 1
the heat of the inductor is dissipated through metal conduction
Data Source
AI summary
An inductor module includes a magnetic material, at least one internal conductor and a thermal conductive frame. The at least one internal conductor is placed within the magnetic material. The thermal conductive frame is placed in the magnetic material and includes an upper structure, a lower structure and a connecting bar. The connecting bar connects the upper structure and the lower structure.