Power Inductor Internal Cooling Passages for Wet Powertrain Integration
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Solution Overview
Problem
Existing power inductors in electric vehicles lack efficient thermal management solutions, particularly when mounted within wet environments like transmission housings, leading to suboptimal thermal performance.
Innovation Solution
The power inductor incorporates an internal cooling circuit with recessed channels and fluid branches that circulate dielectric fluid directly through the core and coils, enhancing thermal management by maintaining direct contact with the magnetic core and conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional power inductors are mounted in wet environments like transmission housings, then the inductor can be integrated into the vehicle powertrain system, but thermal management performance deteriorates due to insufficient cooling
Solution Approach 1:
The patent applies hydraulic cooling by circulating dielectric fluid through internal channels within the inductor assembly. The fluid circuit includes channels formed in the magnetic core and additional channels in the coil former, allowing hydraulic flow to directly cool the hottest components (core and coils) from the inside, transforming the cooling approach from external/conductive to internal/hydraulic.
Solution Approach 2:
The cooling channels are nested within the inductor structure itself - channels are formed inside the magnetic core and the coil former, with the fluid circuit embedded within the assembly. This nesting allows the cooling system to be integrated into the inductor without adding external cooling components, solving the thermal management issue while maintaining compact integration.
2Temperature
If internal cooling channels are added to the inductor, then thermal management is improved, but device complexity increases due to additional fluid circuit components
Solution Approach 1:
The cooling function is merged with the structural components of the inductor. The magnetic core itself is formed with internal cooling channels, and the coil former also contains channels. This merging eliminates the need for separate external cooling plates or heat sinks, reducing overall system complexity while achieving effective thermal management.
Solution Approach 2:
The magnetic core serves dual functions: providing magnetic flux path and serving as a cooling channel structure. The coil former also serves dual purposes: supporting the windings and providing additional cooling channels. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity.
3Temperature
If dielectric fluid is used for cooling, then thermal management effectiveness is improved, but loss of substance increases due to fluid leakage risks
Solution Approach 1:
The dielectric fluid is contained within nested channels formed inside the magnetic core and coil former. These internal channels are fully enclosed within the solid structural components, creating a sealed containment system that prevents fluid leakage while maintaining effective thermal contact between the coolant and the inductor components.
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 internal cooling system effectively manages thermal stress even under heavy duty cycles, improving the inductor's performance and longevity by maintaining efficient thermal management.
Implementation Method 1
The internal cooling system effectively manages thermal stress even under heavy duty cycles, improving the inductor's performance and longevity by maintaining efficient thermal management
Implementation Method 2
a fluid circuit having a first branch disposed between the first leg and the first coil and a second branch disposed between the second leg and the second coil
Data Source
AI summary
A power inductor includes a magnetic core having first and second legs and opposing first and second curved sections, a conductor having a first coil around the first leg and a second coil around the second leg; and a fluid circuit having a first branch disposed between the first leg and the first coil and a second branch disposed between the second leg and the second coil.