Liquid Cooled Power Inductor for EV DC-DC Converters
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Solution Overview
Problem
The inductor assembly in DC-DC converters of electric vehicles generates significant heat, which current thermal management systems fail to effectively address, leading to potential performance degradation and reliability issues.
Innovation Solution
The implementation of a cooling system where transmission fluid contacts and circulates around the inductor assembly, either through splash, spray, or closed loop mechanisms, to efficiently dissipate heat, including the use of a housing that defines a chamber containing dielectric fluid and a pump to circulate the fluid for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the inductor assembly operates at high power, then the power conversion capability is improved, but the heat generation increases leading to thermal management issues
Solution Approach 1:
The patent introduces dielectric fluid as an intermediary cooling medium between the inductor assembly and the environment. The fluid circulates through a closed-loop system, absorbing heat from the inductor and transferring it to a heat exchanger, thereby mediating the thermal management process and enabling high power operation without excessive temperature rise
Solution Approach 2:
The patent employs a hydraulic cooling system where dielectric fluid is pumped through channels surrounding the inductor assembly. The pump-driven fluid circulation creates a controlled hydraulic loop that efficiently removes heat from the inductor, allowing the system to maintain high power conversion capability while managing thermal loads
2Device complexity
If conventional cooling methods are used, then the system structure is simple, but the thermal management effectiveness is insufficient
Solution Approach 1:
The patent merges the cooling function with the inductor assembly by integrating the dielectric fluid channels directly around the inductor core and windings. This combined design ensures that cooling is applied precisely where heat is generated, significantly improving thermal management effectiveness while maintaining reasonable structural complexity
Solution Approach 2:
The patent changes the thermal parameters of the system by introducing dielectric fluid with specific thermal properties and controlling its flow rate through a pump. By adjusting fluid flow parameters and heat exchanger characteristics, the system achieves effective thermal management that conventional air cooling or simple heat sinks cannot provide
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 effectively reduces the inductor assembly's temperature, enhancing its thermal performance, reliability, and overall efficiency of the DC-DC converter in electric vehicles.
Implementation Method 1
An inductor is disposed within the chamber and is in contact with the fluid. The power system also includes a pump configured to circulate the fluid to cool the inductor.
Implementation Method 2
a pump configured to circulate the fluid to cool the inductor
Implementation Method 3
At least one gear is disposed within the housing and is configured to rotate relative to the housing and splash fluid onto the exterior surface portions to cool the inductor assembly.
Data Source
AI summary
A vehicle electrical power system includes a variable voltage converter. The variable voltage converter includes an inductor assembly having a housing that defines a chamber containing dielectric fluid. An inductor is disposed within the chamber and is in contact with the fluid. The power system also includes a pump configured to circulate the dielectric fluid to cool the inductor.