# US 12,119,156 B2 · Inductor thermal management system

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- Number: US 12,119,156 B2
- Document ID: US12119156B2
- Status: Granted
- Kind: B2
- Application number: 18/378,776
- Filed: 2023-10-11
- Published: 2024-04-11
- Granted: 2024-10-15
- Earliest claimed: 2022-10-11
- Assignees: Lunar Energy, Inc.
- Applicants: Lunar Energy, Inc.
- Inventors: Charles Ingalz; Gargi Kailkhura; Mark Daniel Goldman; Bozhi Yang; Christopher McCarthy; Peter H. J. How; Xu She
- Web page: https://patentgrep.com/patent/US12119156B2

## CPC

- H01F 27/085: {Cooling by ambient air}
- H01F 27/025: {Constructional details relating to cooling}
- H01F 27/22: Cooling by heat conduction through solid or powdered fillings
- H01F 41/005: {Impregnating or encapsulating (insulating of windings H01F41/12)}
- H05K 7/20418: {the radiating structures being additional and fastened onto the housing}
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS

## Abstract

In various embodiments, an inductor thermal management system includes an inductor, and a heat sink. The heat sink includes a cavity and a spacer adapted to situate the inductor within the cavity and separate the inductor from at least one wall of the cavity such that heat is transferred from the inductor into the heat sink multi-directionally.

## Claims

### Claim 1

An inductor thermal management system, comprising:
an inductor; and
a heat sink, wherein the heat sink includes:
a cavity, wherein the cavity is filled with a potting material;
a basket adapted to hold the inductor in place within the cavity, wherein the basket includes a frame and at least two open sides permitting the potting material to contact a surface exterior to the at least two open sides; and
a spacer adapted to situate the inductor within the cavity and separate the inductor from at least one wall of the cavity such that heat is transferred from the inductor into the heat sink.

### Claim 2 (depends on 1)

The inductor thermal management system of claim 1, wherein the inductor produces at least 12 watts of heat in operation.

### Claim 3 (depends on 1)

The inductor thermal management system of claim 1, wherein a core of the inductor does not contact the cavity.

### Claim 4 (depends on 1)

The inductor thermal management system of claim 1, wherein a core of the inductor is separated from at least one wall of the cavity.

### Claim 5 (depends on 1)

The inductor thermal management system of claim 1, wherein at least one wall of the cavity includes a notch permitting flow over from the cavity to an adjacent area.

### Claim 6 (depends on 1)

The inductor thermal management system of claim 1, wherein the spacer prevents a core of the inductor from contacting the at least one wall of the cavity.

### Claim 7 (depends on 1)

The inductor thermal management system of claim 1, wherein the spacer is included in the basket.

### Claim 8 (depends on 1)

The inductor thermal management system of claim 1, wherein the basket includes a tab configured to engage with a receptacle in the at least one wall of the cavity to lock the basket into place.

### Claim 9 (depends on 1)

The inductor thermal management system of claim 1, wherein the potting material is adapted to fill at least a portion of the cavity.

### Claim 10 (depends on 1)

The inductor thermal management system of claim 1, wherein:
the heat sink includes a recess adapted to accept a seal; and
sealing the heat sink provides ingress protection and electromagnetic compatibility.

### Claim 11 (depends on 1)

The inductor thermal management system of claim 1, wherein the heat sink includes a plurality of fins.

### Claim 12 (depends on 1)

The inductor thermal management system of claim 1, further comprising another cavity adapted to accept another inductor, wherein the inductor and the other inductor are adjacent to and separated from each other by a divider formed by a shared wall of the cavity and the other cavity.

### Claim 13 (depends on 1)

The inductor thermal management system of claim 1, wherein a wiring extending from the inductor is fastened to the heat sink.

### Claim 14 (depends on 1)

The inductor thermal management system of claim 1, wherein the inductor includes a coil of Litz wire.

### Claim 15 (depends on 1)

The inductor thermal management system of claim 1, wherein the inductor includes a high flux core.

### Claim 16 (depends on 1)

The inductor thermal management system of claim 1, wherein the inductor is inset into a metallic shell that is joined to the heat sink.

### Claim 17 (depends on 1)

The inductor thermal management system of claim 1, wherein at least a portion of the heat sink is made using die-cast.