Segmented Magnetic Core Cooling Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Higher-frequency magnetic devices with low thermal conductivity and insulation barriers face challenges in cooling, leading to significant temperature gradients and hot spots, which limits their application in higher-frequency or higher-power scenarios.
Innovation Solution
The implementation of segmented cores with cooling channels parallel and orthogonal to the magnetic flux direction, utilizing protrusions and gaps to create defined coolant paths, enhances heat removal by increasing the surface area contact with coolant, effectively reducing temperature gradients and hot spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If forced liquid or forced air cooling is used for higher-frequency magnetic devices, then cooling capability is improved, but temperature gradients and hot spots still occur due to low thermal conductivity of the core
Solution Approach 1:
The core is divided into multiple segments with cooling channels between them, allowing coolant to flow directly through the core structure. This segmentation enables distributed cooling across the core volume, reducing temperature gradients and hot spots that occur with conventional external cooling methods.
Solution Approach 2:
Cooling channels are implemented in both the vertical direction (between core segments) and horizontal direction (within core segments), creating a three-dimensional cooling network. This multi-directional approach ensures comprehensive heat removal from all regions of the core, addressing the temperature uniformity issue.
2Reliability
If core-to-winding insulation and inter-winding insulation are added, then electrical isolation is improved, but heat transfer is hindered
Solution Approach 1:
The cooling channels serve as an intermediary thermal pathway that bypasses the insulation barriers. By providing dedicated coolant flow paths between core segments and around windings, the system achieves heat transfer without compromising electrical isolation, as the coolant channels are thermally conductive but electrically isolated through proper design.
3Temperature
If segmented cores with cooling channels are implemented, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The core is divided into multiple segments with cooling channels between them, allowing coolant to flow directly through the core structure. This segmentation enables distributed cooling across the core volume, reducing temperature gradients and hot spots that occur with conventional external cooling methods.
Solution Approach 2:
The cooling channels serve dual purposes: they provide thermal management for the core and also act as structural elements that maintain core segment spacing. This multi-functionality reduces the need for additional dedicated cooling components, thereby limiting the increase in device complexity.
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 approach significantly improves heat dissipation from both the core and windings, enabling the use of magnetic devices in higher-frequency and higher-power applications by reducing temperature gradients and maintaining efficient magnetic properties.
Implementation Method 1
cooling channels configured to transport coolant through the coil assembly or core in order to cool the coil assembly or core
Implementation Method 2
These types of magnetic devices are often cooled using forced liquid or forced air cooling
Implementation Method 3
portions of the segments of the core are separated from one another to form multiple cooling channels in a first direction through the core parallel to a direction of the magnetic flux
Data Source
Figure 1~2A
Figure 2B
Figure 3~4A
AI summary
An apparatus includes a coil assembly, a core, and at least one cooling channel. The coil assembly includes at least one winding configured to receive a varying electrical current. The core includes multiple segments, and the at least one winding is wound around portions of the segments and is configured to generate a magnetic flux. The at least one cooling channel is configured to transport coolant through the coil assembly or core in order to cool the coil assembly or core. Portions of the segments of the core can be separated from one another to form multiple cooling channels through the core, and the multiple cooling channels can be configured to transport coolant through the core. The coil assembly may include at least one insulative spacer having multiple cooling channels, and the multiple cooling channels may be configured to transport coolant through the coil assembly.