Orthogonal Winding Magnetic Core With Integrated Heat Pipe
Solution Overview
Problem
Existing magnetic power units face challenges in compactness and heat dissipation, particularly when operating under high power, making them impractical for high-power applications such as hybrid and electrical vehicles.
Innovation Solution
A compact magnetic power unit is designed with a magnetic core featuring orthogonal windings and a heat dissipation system, comprising multiple partial magnetic cores assembled together with a heat pipe and flux closing covers, allowing for efficient heat dissipation and increased power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a magnetic core with orthogonal windings is used to increase power density, then the power density is improved, but the heat dissipation capability deteriorates
Solution Approach 1:
The magnetic core is divided into multiple segments with cooling channels integrated between them. This segmentation allows heat to be dissipated through the internal channels while maintaining the compact orthogonal winding structure, thus resolving the contradiction between high power density and heat dissipation capability.
Solution Approach 2:
Cooling channels are introduced as intermediary structures within the magnetic core. These channels serve as mediators that facilitate heat transfer from the high-power orthogonal windings to the external cooling system, enabling effective heat dissipation without compromising the compact design.
2Volume of moving object
If the magnetic core size is reduced to achieve compactness, then the volume is improved, but the heat dissipation efficiency deteriorates
Solution Approach 1:
Cooling channels are nested within the magnetic core structure itself, utilizing the internal space of the compact core for heat dissipation purposes. This nesting approach allows efficient heat removal without increasing the external dimensions of the magnetic core.
Solution Approach 2:
Heat dissipation is addressed by introducing internal cooling channels that create a three-dimensional heat transfer pathway within the compact core. This dimensional approach to cooling allows efficient heat removal from the high-power windings without increasing the core's external volume.
3Power
If orthogonal windings are added to increase power capacity, then the power capacity is improved, but the device complexity increases
Solution Approach 1:
The orthogonal windings are implemented as separate modular units that can be independently manufactured and assembled. This segmentation reduces the manufacturing complexity of each individual winding while achieving the overall high power capacity through the combination of multiple orthogonal windings.
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 results in a highly compact magnetic power unit up to 50% smaller than conventional units, with enhanced power density up to 200W/cm³, effectively addressing the issues of size and heat management in high-power applications.
Implementation Method 1
a heat pipe and flux closing covers, allowing for efficient heat dissipation
Implementation Method 2
a magnetic core generally including a first, a second and a third winding channels respectively arranged around a first, a second and a third intersecting axis orthogonal to each other, each of said winding channels intended for receiving at least one coil wound around the magnetic core
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The magnetic poser unit (100) comprises a magnetic core (10) including a first, a second and a third winding channels (2a, 2b, 2c) respectively arranged around a first, a second and a third crossing axis (A-A, B-B, C-C) orthogonal to each other, each of said winding channels (2a, 2b, 2c) being intended for receiving one coil wound around the magnetic core (10), each coil having at least one turn. The crossing axis (A-A, B-B, C-C) define orthogonal planes providing eight octants, each including a protrusion defining a protruding spacer (20), being spaced to each other by said winding channels (2a, 2b, 2c). The magnetic core (10) is a composed core formed by several different partial magnetic cores assembled together including two side partial magnetic cores (12), each including four protruding spacers (20). The magnetic core (10) further includes a through hole (30) housing a device for heat dissipation (50).