Methods for thermal management in inductors

A method of manufacturing a thermal management system, comprising:

• forming a toroidal housing by additive manufacturing, wherein the toroidal housing defines a wall having a groove defined therein;
• positioning a conductor having a greater thermal conductivity than the wall within the groove;
• and
• positioning an inductor in thermal communication with the toroidal housing;
• wherein forming the toroidal housing includes:
• forming the wall having an outer wall and an inner wall, at least one of the outer wall or the inner wall defining an inner surface;
• and
• forming the groove within the inner surface, the groove having a helical shape relative to a central axis of the toroidal housing.

A method, comprising:

• forming a toroidal housing by additive manufacturing, wherein the toroidal housing defines a wall having a groove defined therein;
• positioning a conductor, having a greater thermal conductivity than the wall, in the groove;
• coiling a winding around a toroidal inductor;
• and
• positioning the toroidal inductor in thermal communication with the toroidal housing.