Transformer-based power converters with 3D printed microchannel heat sink
First Claim
1. An electromagnetic component, comprising:
- a core comprising a core winding portion having at least one winding surface;
a winding wrapped around the core winding portion over the at least one winding surface; and
a monolithic heat sink element including a heat-receiving portion positioned between the winding surface of the core and at least a portion of the winding, the heat-receiving portion of the heat sink element formed of a thermally conductive material having at least one closed fluid channel therein which receives a flow of liquid therethrough, a first portion of the at least one fluid channel extends in a first plane, and a second portion of the at least one fluid channel extends in a second plane, the second plane different from the first plane.
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Accused Products
Abstract
Systems and methods that allow for weight and size reduction of electronics components, such as transformer rectifier units (TRUs) or autotransformer rectifier units (ATRUs), by providing a fluid cooling system is utilized to provide high heat dissipation for a transformer assembly of TRUs or ATRUs by providing a thermal interface at the windings of the transformer assembly, which are the hottest spots in such assemblies. The cooling system may include a fluid-cooled winding heat sink element or “finger,” which may be a thermally conductive bar (e.g., aluminum, copper) having microchannels therein positioned between the core and windings of a transformer or between turns of the windings of a transformer. Fluid passes through the microchannels of the heat sink element to provide direct cooling to the heat generating windings of the transformers. The heat sink element may be produced by an additive manufacturing technology.
309 Citations
29 Claims
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1. An electromagnetic component, comprising:
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a core comprising a core winding portion having at least one winding surface; a winding wrapped around the core winding portion over the at least one winding surface; and a monolithic heat sink element including a heat-receiving portion positioned between the winding surface of the core and at least a portion of the winding, the heat-receiving portion of the heat sink element formed of a thermally conductive material having at least one closed fluid channel therein which receives a flow of liquid therethrough, a first portion of the at least one fluid channel extends in a first plane, and a second portion of the at least one fluid channel extends in a second plane, the second plane different from the first plane. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A power converter apparatus, comprising:
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an enclosure at least partially formed of a carbon fiber-reinforced polymer; and a power converter electronics assembly disposed within the enclosure, the power converter electronics assembly including; at least one magnetic component including a core having at least one winding surface and a winding wrapped around the core over the at least one winding surface; and a monolithic heat sink element including a heat-receiving portion positioned between the winding surface of the core and at least a portion of the winding, the heat-receiving portion of the heat sink element formed of a thermally conductive material having at least one fluid channel therein that receives a fluid via a first open end and discharges the fluid via a second open end opposite the first open end. - View Dependent Claims (16, 22, 23, 24, 25, 26, 27, 28, 29)
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17. A method of manufacturing an electromagnetic component, the method comprising:
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providing a core comprising a core winding portion having at least one winding surface; providing a winding wrapped around the core winding portion over the at least one winding surface; providing a three-dimensional design file, the design file specifying a three-dimensional design for a monolithic heat sink element which includes a heat-receiving portion having at least one closed fluid channel therein which receives a flow of liquid therethrough, a first portion of the at least one fluid channel extends in a first plane, and a second portion of the at least one fluid channel extends in a second plane, the second plane different from the first plane; providing the three-dimensional design file to an additive manufacturing system; forming the heat sink element, based on the three-dimensional design file, using the additive manufacturing system; and positioning the heat-receiving portion of the heat sink element between the winding surface of the core and at least a portion of the winding. - View Dependent Claims (18, 19, 20)
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21. A method of manufacturing an electromagnetic component, the method comprising:
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providing a core comprising a core winding portion having at least one winding surface; providing a winding wrapped around the core winding portion over the at least one winding surface; providing a three-dimensional design file, the design file specifying a three-dimensional design for a monolithic heat sink element which includes a heat-receiving portion having at least one fluid channel therein that receives a fluid; providing the three-dimensional design file to an additive manufacturing system; forming the heat sink element, based on the three-dimensional design file, using the additive manufacturing system, wherein forming the heat sink element comprises; converting three-dimensional information in the design file into a plurality of slices that each define a cross-sectional layer of the heat sink element; and successively forming each layer of the heat sink element by fusing a metallic powder using laser energy; and positioning the heat-receiving portion of the heat sink element between the winding surface of the core and at least a portion of the winding.
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Specification