Toroidal Magnetic Element Liquid Cooling via Coil Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Magnetic elements, such as transformers and inductors, face challenges in minimizing size and cost while maintaining efficient heat transfer and reducing eddy losses, particularly in toroidal geometries where high current windings are difficult to fabricate and cool effectively.
Innovation Solution
A toroidal magnetic element design featuring a plurality of coils arranged in a toroidal configuration with alternating winding orientations and spacers, where cooling fluid flows through small gaps between the coils and spacers to facilitate efficient heat transfer, and a housing with a fluid path from the inlet to the outlet to manage coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high current densities and electrical frequencies are used to minimize size and cost, then power density and efficiency are improved, but heat transfer efficiency deteriorates due to increased thermal load
Solution Approach 1:
The patent implements liquid cooling channels integrated within the magnetic core structure, using fluid circulation to actively remove heat from high-current windings. The cooling system includes inlet and outlet ports connected to passages that flow through or adjacent to the core, enabling efficient thermal management while maintaining high power density operation
2Power
If high current windings are used to achieve high current densities, then power processing capability is improved, but manufacturing difficulty increases due to fabrication challenges
Solution Approach 1:
The patent divides the toroidal winding into multiple discrete coil segments that can be manufactured separately using standard winding equipment. These segments are then assembled around the magnetic core with insulating spacers, eliminating the need for specialized toroidal winding machinery while achieving high current density through multiple parallel or series-connected coils
3Power
If toroidal geometry is used to improve magnetic efficiency, then power processing efficiency is improved, but manufacturing complexity increases due to special winding equipment requirements
Solution Approach 1:
The patent breaks the continuous toroidal winding into discrete coil segments that can be manufactured with conventional equipment. The segments are assembled around a segmented magnetic core with insulating spacers positioned between coils, maintaining the beneficial toroidal magnetic path while simplifying manufacturing processes and reducing equipment requirements
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 enhances heat dissipation and reduces eddy losses, allowing for higher current densities and improved power processing efficiency while maintaining a compact and cost-effective magnetic element.
Implementation Method 1
Cooling fluid flows through the gaps to cool the coils
Implementation Method 2
efficient heat transfer from the winding and core
Implementation Method 3
a contribution to a magnetic field at the center of the first coil, from a current flowing through both coils in series
Data Source
AI summary
A toroidal magnetic element. A plurality of coils is arranged in a toroidal configuration. Each coil may be a hollow cylinder, formed by winding a rectangular wire into a roll. The coils alternate with spacers, each of which may be a wedge. The coils may alternate in winding orientation, and the inner end of each coil may be connected, through a connection pin, to the inner end of an adjacent coil. Small gaps are formed between the coils and the wedges, e.g. as a result of each wedge having, on its two faces, a plurality of raised ribs, against which the coils abut. Cooling fluid flows through the gaps to cool the coils.