Toroidal Inductor Assembly with Wire Guide for Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In aerospace engine systems, traditional electrical inductors are bulky due to heavy components, which reduces aircraft efficiency, and minimizing their size compromises flux capacity and heat dissipation.
Innovation Solution
A circular inductor core with a wire guide having specific slots for winding wires, a heat sink for thermal management, and insulating material for electrical insulation and thermal coupling, allowing for efficient heat dissipation while maintaining electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the size of an inductor is reduced, then the weight and size of the inductor are minimized, but the flux capacity and heat dissipation surface area are reduced
Solution Approach 1:
The patent transitions from traditional planar winding layouts to a three-dimensional toroidal core structure with wires wrapped around the circular cross-section. This dimensional change allows the wires to be arranged in multiple layers and positions around the core, significantly increasing the effective heat dissipation surface area and flux capacity within a compact volume. The toroidal geometry enables wires to be positioned at optimal radial distances from the core center, maximizing both magnetic coupling and thermal radiation surfaces.
Solution Approach 2:
The patent implements a nested structure where multiple wires are wrapped around the same toroidal core in concentric layers. The first wire forms an initial winding, and subsequent wires are wrapped around the same core structure, creating a nested arrangement. This nesting allows multiple functional wires to occupy the same spatial envelope, maintaining high flux capacity and heat dissipation surface area without proportionally increasing the overall inductor volume or weight.
2Volume of moving object
If the size of an inductor is reduced, then the size and weight of the inductor are minimized, but the manufacturing complexity increases
Solution Approach 1:
The patent introduces a toroidal core as an intermediary structure that simplifies the winding process. The circular cross-section of the toroidal core provides a naturally guiding geometry that directs the wire path, reducing the need for complex winding fixtures or automated positioning systems. The core acts as a physical template that maintains consistent wire spacing and tension, making the manufacturing of compact multi-layer windings more straightforward compared to planar inductor designs.
Solution Approach 2:
The patent employs a toroidal (doughnut-shaped) core with a circular cross-section, utilizing curved geometry to simplify wire routing. The continuous circular path around the toroidal core eliminates the need for sharp corners or complex angular transitions that would complicate the winding process. This curvature allows wires to be wrapped smoothly in concentric layers, reducing manufacturing complexity while achieving compact volume.
3Reliability
If traditional inductor designs are used, then the flux capacity is maintained, but the weight and size increase
Solution Approach 1:
The patent employs a composite structure combining the toroidal core material with multiple insulated wire windings arranged in concentric layers. This composite arrangement allows the magnetic flux to be contained and guided efficiently within the toroidal core geometry, maintaining high flux capacity. The compact toroidal shape with dense wire packing achieves superior flux utilization per unit weight compared to traditional linear or planar inductor designs, reducing overall inductor weight while preserving flux capacity.
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 enables a compact, high-capacity electrical inductor with improved heat dissipation, addressing the size and weight issues of traditional inductors in aerospace applications.
Implementation Method 1
a heat sink thermally coupled to the wire guide
Implementation Method 2
an insulating material placed in the slots containing the wires to electrically insulate the wires
Data Source
Figure 1
Figure 2~4
Figure 3A~3B
AI summary
An electrical inductor assembly comprises an inductor core having a circular shape, a wire guide (24) that surrounds the inductor core and includes a plurality of slots (36), at least one of the slots forming a path winding around the inductor core, and at least one wire (22a, b, c) placed in one of the plurality of slots to form a winding. A method of forming an electrical inductor assembly comprises forming an inductor core having a circular shape, surrounding the inductor core with a wire guide, winding at least one wire around the inductor core along a slot in the wire guide, and applying an insulating material to the slot containing the at least one wire to electrically insulate the at least one wire.