SMC Inductor Thermal Management via Integrated Core Cooling
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Solution Overview
Problem
Current inductor designs face challenges in effective thermal management due to mechanical complexities and inefficiencies in cooling, particularly with liquid cooling methods, which lead to increased size, weight, and cost, and limited optimization possibilities, as well as thermal inhomogeneities and leakage risks.
Innovation Solution
An inductor design featuring a Soft Magnetic Composite (SMC) core with an annularly wound coil integrated into the core, utilizing thermal connecting fixtures and integrated cooling pipes to facilitate direct thermal conduction to an external heat receiver, enhancing heat transfer and reducing size and weight while maintaining high thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling is introduced into traditional inductor structures, then cooling efficiency is improved, but mechanical complexity increases and leakage risks arise
Solution Approach 1:
The patent merges the cooling function directly into the core structure by integrating cooling channels within the SMC core itself, rather than adding separate liquid cooling systems. This integration eliminates the need for external cooling pipes and connections, reducing mechanical complexity while maintaining effective heat removal from the coil.
Solution Approach 2:
The SMC core material acts as an intermediary thermal conductor, transferring heat from the coil to the cooling channels embedded within it. This intermediary approach allows efficient heat transfer without requiring direct liquid contact with the coil, reducing leakage risks while maintaining cooling efficiency.
2Ease of manufacture
If standard bobbins with low thermal conductivity are used, then coil winding is simplified, but thermal barrier is created reducing cooling efficiency
Solution Approach 1:
The patent extracts or eliminates the traditional bobbin component entirely by winding the coil directly onto the SMC core form. This removal of the low thermal conductivity bobbin eliminates the thermal barrier while simplifying the overall structure, as the SMC core itself serves as the winding form.
3Temperature
If thermally conductive polymer materials are used to fill pot cores, then thermal properties are improved, but thermal conductivity remains low below 1.5 W/m*K
Solution Approach 1:
The patent uses SMC (Soft Magnetic Composite) material which is a composite consisting of magnetic powder particles embedded in an insulating binder matrix. This composite structure provides both the necessary magnetic properties and significantly improved thermal conductivity compared to polymer filling materials, as the metallic powder particles create thermal conduction pathways through the material.
4Temperature
If aluminium housing with cooling pipes is used, then cooling capability is enhanced, but weight and space increase
Solution Approach 1:
The patent merges the housing, core, and cooling structure into a single integrated SMC core component. The cooling channels are formed directly within the core material rather than being separate aluminium housing features, eliminating the need for additional aluminium housing and reducing both weight and space requirements while maintaining cooling capability.
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 design enables efficient cooling, reducing the inductor's size and weight, allowing for higher energy content without overheating, and simplifies assembly and production, while minimizing the impact on magnetic properties.
Implementation Method 1
the core material acts as a thermal conductor having thermal conductivity above 1,5 W/m*K, conducting heat from said coil
Implementation Method 2
said cooling pipe/pipes are adapted to accommodate a flow of a fluid for transporting heat from said coil towards an external cooler
Data Source
Figure 1~2
Figure 3~4a
Figure 4b~5a
AI summary
The invention relates to an inductor (1) having a coil (2) and a core (3), wherein the core (3) is made of a Soft Magnetic Composite (SMC), the coil (2) is composed of a annularly wound electrical conductor, the coil (2) is substantially integrated into said core (3) so that the core (3) material acts as a thermal conductor having thermal conductivity above 1,5 W/m*K more preferably 2 W/m*K most preferably 3 W/m*K, conducting heat from said coil (2), wherein the inductor (1) is in thermal connection with at least one thermal connecting fixture (10-25), wherein said at least one thermal connecting fixture(10-25) is adapted to be connected to a first external heat receiver (4) so as to conduct heat from the inductor to said first external heat receiver (4).