Liquid Cooled Inductor Assembly with Nested Cooling Conduit
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Solution Overview
Problem
Conventional inductor assemblies have limited current carrying capability due to heat generated by current flowing through conductive wires, which restricts core size, material selection, and reliability, necessitating improved cooling solutions.
Innovation Solution
An inductor assembly with a cooling element featuring a coolant conduit that includes integral insert and base portions with channel segments, such as axially aligned, radial, helical, and spiral portions, seated within the inductor core cavity and between the core and cold plate, facilitating efficient heat dissipation through coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional inductor assemblies operate without liquid cooling, then the structure remains simple and manufacturing is easier, but the current carrying capability is limited due to heat generation
Solution Approach 1:
The cooling element is nested within the inductor core cavity. The insert portion fits inside the toroidal core's central cavity, and the base portion sits between the core and cold plate, creating a compact nested arrangement that provides liquid cooling without significantly increasing external dimensions or structural complexity
Solution Approach 2:
A coolant conduit filled with liquid coolant serves as an intermediary heat transfer medium. The coolant absorbs heat from the windings and core through thermal conduction and convective flow, effectively removing harmful heat generation while maintaining a relatively simple structural addition
2Power
If the current rating of the inductor assembly is increased, then the power handling capability is improved, but the temperature of the core and windings increases reducing reliability
Solution Approach 1:
The liquid coolant continuously circulates through the cooling element, providing continuous heat removal from the inductor core and windings. This continuous cooling action maintains lower operating temperatures even at increased current ratings, thereby preserving reliability while enabling higher power handling
Solution Approach 2:
A liquid cooling system using hydraulic flow of coolant through channels in the cooling element provides efficient heat removal. The fluid dynamics of coolant circulation enable effective thermal management that supports higher current ratings without compromising core and winding reliability
3Productivity
If liquid cooling is implemented in the inductor assembly, then the current carrying capability is enhanced, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The cooling system is segmented into distinct components: an insert portion that fits within the core cavity and a base portion that interfaces with the cold plate. This segmentation allows for separate manufacturing of cooling components and simplified assembly by placing the insert into the core cavity and positioning the base between the core and cold plate
Solution Approach 2:
The insert portion of the cooling element is nested within the central cavity of the toroidal core, utilizing the existing internal space. This nesting approach allows integration of the cooling function without requiring additional external space or complex structural modifications to the inductor assembly
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 enhances the current handling capacity and thermal margin of the inductor assembly, maintaining the core at a lower temperature and reducing temperature variations, thereby improving the filtering effect and reliability.
Implementation Method 1
a coolant conduit adjacent the winding portions in core and between the core and cold plate, wherein the coolant conduit extends from a first end of the cavity toward an opposed second end of the cavity
Implementation Method 2
facilitating efficient heat dissipation through coolant flow
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
An inductor assembly (100) includes an inductor core (102), a winding (104), and a coolant conduit (126). The inductor core defines a cavity (103) and the winding is disposed about the inductor core such that a portion of the winding is disposed within the cavity. The coolant conduit extends from a first end of the cavity towards an opposed second end of the cavity and includes an inlet port (128) and an outlet port (130) in fluid communication with each other through the coolant conduit.