Magnetic Core Cooling Channels for Inductor Heat Dissipation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional inductors with magnetic cores made of iron or ferrite suffer from energy losses due to eddy currents and hysteresis, leading to heat dissipation, and the reflow soldering process can damage electronic components with high temperatures.

Innovation Solution

An additive manufacturing process creates a magnetic component with integrated cooling channels using a ferrimagnetic material for the core and a thermally conductive, electrically insulative material for the duct, allowing for efficient heat dissipation and eliminating the need for external cooling devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional magnetic cores made of iron or ferrite are used, then high magnetic permeability and increased inductance are achieved, but energy losses due to eddy currents and hysteresis increase, causing heat dissipation

Engineering Contradiction:

Improveenergy lossVSAvoidheat dissipation

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The patent converts the harmful heat generated by eddy currents and hysteresis losses into a manageable thermal management problem by integrating cooling channels directly into the magnetic core. The cooling channels allow coolant to flow through the core, actively removing heat at its source and transforming the harmful thermal effect into a controlled cooling process.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The cooling channels are nested within the magnetic core structure itself, with ducts formed inside the ferrite material. This nested configuration allows the cooling system to be embedded within the magnetic component, enabling direct heat removal from the core without requiring external cooling apparatus.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If reflow soldering process is used to attach inductors to PCB, then permanent solder joints are formed, but high temperatures cause damage to electronic components on the printed circuit board

Engineering Contradiction:

Improvesolder joint strengthVSAvoidthermal damage to components

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent performs preliminary cooling by establishing coolant flow through the integrated channels before the reflow soldering process begins. The coolant is already circulating and ready to absorb heat, creating a thermal management system that activates in advance to prevent thermal damage during the high-temperature soldering operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coolant acting as an intermediary substance absorbs the thermal energy from the magnetic core during reflow soldering. The coolant serves as a heat transfer medium between the core and the external cooling system, protecting sensitive electronic components on the PCB from direct exposure to high temperatures.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If external cooling devices are used to manage heat from magnetic cores, then heat dissipation is achieved, but device complexity and manufacturing costs increase

Engineering Contradiction:

Improveheat dissipationVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the magnetic core structure with the cooling system by integrating channels directly into the ferrite core. This combination eliminates the need for separate external cooling devices, as the core itself becomes the heat exchange structure, reducing overall system complexity and component count.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The magnetic core serves multiple functions: it provides magnetic permeability for inductance, structural support, and integrated thermal management through embedded cooling channels. This multi-functionality eliminates the need for dedicated external cooling components, simplifying the overall device architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 provides superior cooling capabilities, reduces manufacturing costs and time, and prevents damage to components during the soldering process by integrating cooling channels within the magnetic core, enhancing the performance and reliability of inductive components.

Implementation Method 1

a duct formed of a second material extending at least partially through the body between the first inlet opening and the second outlet opening, the first inlet opening and the second outlet opening being in fluid communication by way of the duct

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

a thermally conductive, electrically insulative material for the duct, allowing for efficient heat dissipation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240177912A1Magnetic component and method of forming

Publication Date: 2024.05.30 GE AVIATION SYSTEMS LLC

AI summary

A component includes a magnetic core having a body formed of a first material, defining a first opening and a second opening thereon. A duct formed of a second material extends at least partially through the body between the first opening and the second opening. The first opening and the second opening are in fluid communication by way of the duct.