Toroidal Magnetic Element With Liquid Cooling Gaps
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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 spacers, where cooling fluid flows through small gaps between the coils and wedges, enhancing heat transfer and reducing eddy losses by optimizing the arrangement of coils and core segments for efficient fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high current densities and electrical frequencies are used to minimize size and cost, then productivity and power density are improved, but heat transfer efficiency deteriorates and eddy losses increase
Solution Approach 1:
The magnetic element is divided into multiple discrete coils arranged in a toroidal configuration, with each coil separated by spacers. This segmentation allows cooling fluid to flow through multiple channels between coils and spacers, significantly improving heat dissipation while maintaining high power density.
Solution Approach 2:
A liquid cooling system is implemented where cooling fluid flows through gaps between coils and spacers. The hydraulic flow path is designed to efficiently remove heat from the windings, enabling high current densities without thermal overload.
2Reliability
If toroidal geometry is used to improve magnetic efficiency, then magnetic properties are improved, but manufacturing complexity increases due to special winding equipment requirements
Solution Approach 1:
The toroidal magnetic element is constructed from multiple discrete coil segments rather than a continuous winding. Each coil can be manufactured separately using standard winding equipment, then assembled into the toroidal configuration with spacers, greatly simplifying manufacturing while preserving magnetic efficiency.
Solution Approach 2:
Multiple discrete coils are combined to form the complete toroidal magnetic element. The coils are arranged and interconnected to achieve the desired magnetic properties, allowing modular assembly and simplifying the manufacturing process.
3Volume of stationary object
If coil density is increased to reduce size, then volume is reduced, but heat transfer efficiency deteriorates due to reduced cooling channels
Solution Approach 1:
The cooling system utilizes the radial dimension by flowing fluid through gaps between coils and spacers in the radial direction. This three-dimensional cooling approach allows efficient heat removal even when coil density is high, as the cooling channels are distributed throughout the volume rather than confined to a single plane.
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 design achieves improved heat dissipation and reduced eddy losses, allowing for higher current densities and efficient magnetic field contributions while maintaining a compact and cost-effective structure.
Implementation Method 1
Cooling fluid flows through the gaps to cool the coils
Implementation Method 2
a contribution to a magnetic field at the center of the first coil, from a current flowing through both coils in series, is in the same direction as a contribution to the magnetic field from the current flowing through the second coil
Data Source
AI summary
A magnetic element. In some embodiments, the magnetic element includes a first electrically conductive coil, having a first annular surface and a second annular surface; a second electrically conductive coil, having a first annular surface and a second annular surface; and a spacer between the first electrically conductive coil and the second electrically conductive coil; a fluid inlet; and a fluid outlet. The spacer may have a first face, the first face being separated from the first annular surface of the first electrically conductive coil by a first gap; and a fluid path may extend from the fluid inlet to the fluid outlet through the first gap.