# US 12,009,144 B2 · Cooled / cast inductor apparatus and method of use thereof

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- Number: US 12,009,144 B2
- Document ID: US12009144B2
- Status: Granted
- Kind: B2
- Application number: 16/727,838
- Filed: 2019-12-26
- Published: 2020-06-11
- Granted: 2024-06-11
- Earliest claimed: 2007-04-05
- Applicants: Grant A. MacLennan; Hans Wennerstrom; Steve Schiffer
- Inventors: Grant A. MacLennan; Hans Wennerstrom; Steve Schiffer
- Web page: https://patentgrep.com/patent/US12009144B2

## CPC

- H01F 27/2895: {Windings disposed upon ring cores}
- H01F 27/085: {Cooling by ambient air}
- H01F 27/10: Liquid cooling
- H01F 27/255: made from particles (H01F27/26 takes precedence)
- H01F 27/266: {Fastening or mounting the core on casing or support (on coil H01F27/30)}
- H01F 27/2823: {Wires (H01F27/2866 takes precedence)}
- H01F 27/2876: {Cooling (cooling transformers and inductances in general H01F27/08)}
- H01F 27/306: {Fastening or mounting coils or windings on core, casing or other support}
- H01F 27/324: {Insulation between coil and core, between different winding sections, around the coil; Other insulation structures}
- H01F 27/327: {Encapsulating or impregnating (encapsulating coil and core H01F27/022)}
- H01F 37/00: Fixed inductances not covered by group H01F17/00
- H02M 1/126: {using passive filters}
- H01F 1/24: the particles being insulated
- H01F 27/08: Cooling (heat-transfer elements F28F); Ventilating (structural details of casings H01F27/02)
- H01G 4/38: Multiple capacitors, i.e. structural combinations of fixed capacitors
- H01G 4/40: Structural combinations of fixed capacitors with other electric elements, the structure mainly consisting of a capacitor, e.g. RC combinations
- H02M 1/123: {Suppression of common mode voltage or current}
- Y02B 70/10: Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS

## Abstract

The invention comprises an apparatus, comprising: a toroid shaped inductor and a cooling jacket including at least two sections joined to encase the toroid shaped inductor, where the cooling jacket has an inner toroid shaped surface separated by a coolant flow gap from the toroid shaped inductor. Optionally, the inductor comprises a cast winding, a cast heat sink element of the cast winding protruding from a longitudinal length of a turn of the winding, and/or a distributed gap pressed powder inductor core.

## Claims

### Claim 1

An apparatus, comprising:
a toroid shaped inductor, said toroid shaped inductor comprising:
an inductor core, said inductor core comprising:
a plurality of coated particles comprising an average particle size of less than one hundred micrometers, each of a majority of said coated particles comprising:
at least three layers;
a first set of alternating substantially magnetic layers; and
a second set of alternating substantially non-magnetic layers,
an inductor winding about at least a section of said inductor core, said winding configured to transmit a current of at least fifty amperes,
said toroid shaped inductor configured to carry a magnetic field of less than 7,000 Gauss at an absolute Oersted value of at least 200,
said coated particles about evenly distributed in at least a portion of said inductor core; and
a cooling jacket, said cooling jacket comprising at least two sections, wherein said at least two sections of said cooling jacket join to encase said toroid shaped inductor.

### Claim 2 (depends on 1)

The apparatus of claim 1, said at least two sections of said cooling jacket comprising:
a first cooling jacket section comprising a first inner surface; and
a second cooling jacket section comprising a second inner surface, said first inner surface and said second inner surface forming a toroid shape encompassing said toroid shaped inductor.

### Claim 3 (depends on 1)

The apparatus of claim 1, said inductor core further comprising a first core section and a second core section, said first core section comprising an insertion geometry inserted in a receiving geometry of said second core section.

### Claim 4 (depends on 3)

The apparatus of claim 3, said toroid shaped inductor further comprising:
a cast winding section.