Core cooling for electrical components

• US 7,129,808 B2
• Filed: 09/01/2004
• Issued: 10/31/2006
• Est. Priority Date: 09/01/2004
• Status: Expired due to Fees

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Kehl, Dennis L., Kaishian, Steven C., Roebke, Timothy A., Siebert, William K., Day, Scott D.
• Primary Examiner(s): Mai, Anh
• Application Number:
  US10/932,244
• Publication Number:
  US 20060044103A1
• Time in Patent Office: 790 Days
• Field of Search: 336/198, 336/208, 336/192, 336/55, 336 57- 62, 361/676, 361/677, 361/699, 361/618, 361/620
• US Class Current: 336/55
• CPC Class Codes: H01F 27/06 Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
• CPC Class Codes: H01F 27/10 Liquid cooling
• CPC Class Codes: H01F 27/322 the insulation forming channels for circulation of the fluid
• CPC Class Codes: H01F 27/325 Coil bobbins formers for coils in general H01F5/02
• CPC Class Codes: H01F 5/02 wound on non-magnetic supports, e.g. formers

Abstract

A cooling system is provided for electrical components in which cooling assemblies (11, 45) are inserted in non-magnetic cores of the electrical components, and in which tubes provide both inflow and outflow of a cooling medium. The non-magnetic cores may be bobbins (30) for an inductor assembly or the core of a capacitor (40). The tubes may form a loop (11) in more than one plane to prevent inducing current in a single turn, or they may be split-flow closed-end tubes (45) inserted from one end of the electrical component. The bobbin cores (31) are also constructed with a non-conductive portion to prevent inducing a current in a single turn of a conductor.

Claims

1. A bobbin assembly for an electrical component, the bobbin assembly having:

a bobbin core of non-magnetic, conductive material having a central opening therethrough and having two portions spaced apart to form a non-conducting portion therebetween;

a bobbin member disposed over the core, the bobbin member being made of a dielectric material;

an electrical component including a coil having a plurality of turns disposed over the bobbin member;

a pair of end pieces of dielectric material disposed on opposite ends of the bobbin core and extending parallel to the plurality of turns; and

wherein at least one hole is formed in said end pieces and said bobbin core, the hole passing through the core in a direction normal to the plurality of turns, said hole being adapted to accept a tube for a cooling medium and for circulating the cooling medium within the bobbin core to cool the electrical component.

2. The bobbin assembly of claim 1, wherein the electrical component is an inductor disposed around said bobbin member.

3. The bobbin assembly of claim 1, wherein the spaced apart portions prevent a complete circuit in which a current could be induced in any plane normal to the plurality of turns and wherein the non-conducting portion between the two portions of the bobbin core is an air gap.

4. The bobbin assembly of claim 1, wherein the spaced apart portions prevent a complete circuit in which a current could be induced in any plane normal to the plurality of turns and wherein the non-conducting portion between the two portions of the bobbin core is provided at least in part by a dielectric material.

5. The bobbin assembly of claim 1, wherein the bobbin core is formed of aluminum.

6. The bobbin assembly of claim 1, wherein the holes are formed in said end pieces and in said bobbin core and are disposed nearer to two corners of the bobbin core than to two opposite corners of the bobbin core.

7. The bobbin assembly of claim 1, wherein the holes are formed in said end pieces and said bobbin core and are disposed along a plane of symmetry running from front to back through the bobbin assembly.

8. The bobbin assembly of claim 1, in combination with a conduit assembly including pass-through conduits for conveying a cooling medium through the holes from an inlet to an outlet.

9. The combination of claim 8, wherein the conduit assembly forms a loop that lies in more than one plane.

10. The bobbin assembly of claim 1, in combination with a conduit assembly including closed-end tubes for conveying a cooling medium into and out of the tubes to provide a split flow.

11. The combination of claim 10, wherein said closed-end tubes have a partition therein for dividing an interior of the tube into an inflow portion and an outflow portion.

12. An inductor assembly for receiving cooling components, the inductor assembly comprising:

a pair of coil assemblies, each having an opening therethrough;

a magnetic core having legs for passing through respective openings in the coil assemblies;

wherein the coil assemblies each include

a bobbin core of non-magnetic material having a central opening therethrough and having two portions spaced apart to form a non-conductive part therebetween;

a bobbin member disposed over the core, said bobbin member being made of a dielectric material;

an electrical component including a coil having a plurality of turns disposed over the bobbin member;

a pair of end pieces of dielectric material disposed on opposite ends of the bobbin and extending parallel to the plurality of turns; and

a pair of holes formed in said end pieces and extending into said bobbin core in a direction normal to the plurality of turns, said holes being adapted to accept tubes for a cooling medium and for circulating the cooling medium within the bobbin core to cool the electrical component.

13. The inductor assembly of claim 12, in combination with a conduit assembly including pass-through conduits for conveying a cooling medium through the holes from an inlet to an outlet of the holes.

14. The combination of claim 13, wherein the conduit assembly forms a loop that lies in more than one plane.

15. The bobbin assembly of claim 12, in combination with a conduit assembly including closed-end tubes for conveying a cooling medium into and out of the holes to provide a split flow.

16. The combination of claim 15, wherein said closed-end tubes have a partition therein for bisecting an interior of the tube into an inflow portion and an outflow portion.