Advance Cooling Designs for High Temperature Transformers and Inductors for Power Electronics

As a result of continuing advances in magnetic materials, compression of circuit physical architecture, increase in magnetic component packaging density and faster switching speed, the heat dissipation rate of next generation military power converter systems will require operation at significantly higher heat flux levels than current power converters. The goal of this SBIR Phase I program is the development of novel magnetic materials with optimal characteristics to meet the required high temperature and electrical operating requirements for military power converters. A further goal of this program is the development of a thermal management approach that utilizes a phase change process coupled with the use of a unique high thermal conductivity 3-D carbon structure to meet the power converter heat dissipation requirements. The design of the 3-D carbon structure would be engineered to provide a high surface area to volume ratio heat exchanger element that would enable a compact, light-weight highly effective heat exchanger device. Further, the design of the 3-D carbon structure will ensure that the local heat flux within the active heat exchange device is sufficient to maintain the power converter operation for continuous and pulse power operation. The proposed thermal management concept will be capable of maintaining the magnetic components at or below their required maximum operating temperature, thus, ensuring system reliability and life.