Toroidal Inductor Cooling via Direct Coolant Contact

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Solution Overview

Problem

Conventional inductor cooling systems incur temperature rises due to thermal interfaces and conduction, as they encase components in conductive casings with coolant flow inside cold plates, rather than utilizing direct contact for efficient heat transfer.

Innovation Solution

A system that houses a toroidal inductor with direct contact between the inductor's winding and coolant, using a secondary housing with coolant lines to facilitate direct convective heat transfer, and employs potting material with low electrical conductivity to secure and seal the inductor within the housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional cooling systems use conductive casings with coolant flow inside cold plates, then the inductor is protected and cooled, but temperature rises occur due to thermal interfaces and conduction

Engineering Contradiction:

Improveinductor temperatureVSAvoidheat transfer efficiency

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent extracts the inductor from its conventional enclosed cooling system and exposes it directly to coolant flow. The inductor is mounted in an open configuration where coolant can directly contact the winding, eliminating the intermediate conductive casing and cold plate structure that caused thermal interface resistance and energy loss.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent eliminates the intermediary conductive casing and cold plate between the inductor and coolant. By removing these intermediate thermal conduction paths, the system achieves direct convective heat transfer from the inductor winding to the coolant, improving heat transfer efficiency and reducing temperature rise.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If direct contact between inductor and coolant is implemented, then heat transfer efficiency improves, but coolant leakage risk increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidcoolant leakage prevention

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent uses a potting material that forms a sealed encapsulation around the inductor winding. This flexible sealing structure allows direct coolant contact with the winding for efficient heat transfer while simultaneously preventing coolant leakage, resolving the contradiction between heat transfer efficiency and reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs a composite structure combining the inductor winding with a potting material that provides both mechanical support and sealing functionality. This composite approach enables direct coolant contact for heat transfer while the potting material's sealing properties prevent coolant leakage, achieving both heat transfer efficiency and reliability.

Inventive Principle:

Principle #40Composite materials

3Reliability

If potting material is used to seal the inductor, then coolant leakage is prevented, but electrical conductivity may increase

Engineering Contradiction:

Improvecoolant leakage preventionVSAvoidelectrical conductivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies potting material with specific local properties - selecting materials with low electrical conductivity to ensure that the sealing function does not compromise electrical isolation. The potting material is applied locally around the inductor winding to provide sealing while maintaining appropriate electrical properties for the application.

Inventive Principle:

Principle #3Local quality

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 eliminates temperature rises by enabling direct convective heat transfer, effectively cooling the inductor while preventing coolant leakage and maintaining low electrical conductivity, thus enhancing heat dissipation and reducing the risk of damage.

Implementation Method 1

a coolant channel defined between the toroidal inductor and the secondary housing through which the coolant flows such that the coolant physically contacts the winding of the toroidal inductor

Methodology Applied

Scientific EffectConvective heat transfer: Convection

Implementation Method 2

The system includes a potting material located between the toroidal inductor and the inductor housing

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3499524B1System for housing and cooling a toroidal inductor

Publication Date: 2021.02.24 HAMILTON SUNDSTRAND CORP

Figure 1A~1C
Figure 2
Figure 3

AI summary

An inductor housing for housing an inductor having a core and a winding includes an outer annular wall and a third wall extending inward from the outer annular wall such that the outer annular wall and the third wall at least partially define an annular cavity configured to receive the inductor. The inductor housing further includes an attachment feature configured to couple the inductor housing to a secondary housing. The inductor is configured to be enclosed within the annular cavity and the secondary housing, and coolant from a coolant supply is configured to flow past the annular cavity and contact the winding of the inductor.