Magnetic Core Apertures for Direct Heat Conduction
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Solution Overview
Problem
Magnetic components in high-power applications face challenges with inefficient heat dissipation due to high thermal resistance between the magnetic assembly and heat sinks, leading to impaired performance and increased costs from using expensive thermal conductors.
Innovation Solution
Incorporating thermally conductive insulator elements within the magnetic core's apertures, which are filled with high-conductivity materials like sintered alumina or ceramic, to create a direct and efficient heat path to cooled plates, reducing thermal resistance and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If expensive thermal conductors are used to improve heat dissipation, then thermal resistance is reduced, but production costs increase
Solution Approach 1:
The patent applies local quality by filling only the critical apertures within the magnetic core with thermally conductive insulator material, rather than using expensive thermal conductors throughout the entire assembly. This localized approach concentrates thermal management resources where they are most needed - at the heat generation sources within the core - while avoiding unnecessary costs in other areas.
Solution Approach 2:
The thermally conductive insulator material serves as an intermediary substance that bridges the thermal gap between the magnetic core and the cooling system. This intermediary fills the apertures to create efficient thermal pathways while maintaining electrical insulation, replacing the need for more expensive direct thermal contact solutions.
2Reliability
If traditional cooling methods are used, then manufacturing is simpler, but thermal resistance remains high causing impaired performance
Solution Approach 1:
The patent segments the cooling function by dividing the core into multiple sections with discrete apertures that are individually filled with thermal conductive material. This segmentation allows heat from different winding regions to be evacuated through dedicated pathways, improving overall thermal management effectiveness without requiring a completely complex cooling system architecture.
Solution Approach 2:
The thermally conductive insulator material is nested within the apertures of the magnetic core structure. This nested arrangement integrates the thermal management function directly into the core geometry, allowing the cooling solution to be embedded within the existing structure rather than added as a separate external system.
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 enables magnetic components to operate at lower temperatures with improved manufacturability and power density, while being more economical, particularly suitable for automotive and hybrid vehicle onboard chargers.
Implementation Method 1
the aperture is filled with a thermal conductors of a non-magnetic insulator material
Data Source
AI summary
A magnetic component having a core of a high-permittivity material with one or more apertures extending between two opposite faces of the core and filled with a thermal conductors of a non-magnetic insulator material. Preferably, the apertures extending between a flat side of the core in contact with a metallic housing and the space where the windings are laid, providing a short and direct path for heat transfer. The thermal conductors may be alumina or any suitable material.