Inductor Winding Cooling via Core Window Heat Conduction
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Solution Overview
Problem
Inductors and chokes in DC power distribution networks face challenges with high copper temperatures due to limited space in the core window area, leading to reduced conduction area and increased weight and size, which affects power density and insulation reliability.
Innovation Solution
A cooling device with a heat conducting element that extends into the core window area, thermally coupled to a heat sink, providing an additional thermal conduction path using heat pipes or high thermal conductivity materials to efficiently transfer heat away from the winding segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If more winding turns are accommodated in the core window area, then inductance value increases, but copper temperature increases due to reduced conduction area
Solution Approach 1:
The patent introduces a third dimension for heat dissipation by extending a heat conducting element vertically into the window area from the heat sink. This spatial arrangement creates a new thermal conduction path that does not interfere with the electrical conduction area of the windings, effectively separating the electrical and thermal dimensions to resolve the contradiction between high inductance and temperature control
Solution Approach 2:
The heat conducting element acts as an intermediary between the winding segments and the heat sink. It provides a dedicated thermal conduction path that transfers heat away from the windings without interfering with their electrical function, allowing more turns to be accommodated without excessive temperature rise
2Power
If more winding turns are fitted in a fixed core, then inductance increases, but conduction area per winding turn decreases
Solution Approach 1:
The patent segments the thermal management function from the electrical function by introducing a separate heat conducting element. This allows the window area to be divided into electrical conduction space for the windings and thermal conduction space for the heat sinking, enabling more winding turns without reducing the effective conduction area
3Power
If cooling is provided for winding segments, then current density increases, but device complexity increases
Solution Approach 1:
The heat conducting element is designed to perform multiple functions: it provides thermal conduction from the windings, serves as a structural support within the window area, and interfaces with the existing heat sink. This multi-functionality reduces the need for additional dedicated cooling components, thereby limiting the increase in device complexity while achieving high current density
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
Enhances current density and power density of inductors and chokes while reducing peak temperatures, improving insulation reliability and extending their lifetime.
Implementation Method 1
The cooling device is configured to provide for the cooling of the window area of a core and of the winding segments arranged in such window area by providing a heat conducting element. One section of the heat conducting element is arranged in and thermally coupled to the window area to absorb heat, and another section of the heat conducting element is thermally coupled to and cooled by a heat sink, thereby providing for an additional thermal conduction path from the window area to the heat sink.
Implementation Method 2
another section of the heat conducting element is thermally coupled to and cooled by a heat sink
Data Source
AI summary
A cooling device for an inductor winding includes an inductor assembly that has a magnetic core and a multi-turn winding wound around the magnetic core. The magnetic core has a window area. Inner winding sections of the multi-turn winding are arranged in the window area. The cooling device also includes a heat sink and a heat conducting element. The heat conducting element has a first section that is thermally coupled to the heat sink, and a second section that extends angularly with respect to the first section. The second section extends into the window area of the magnetic core.