What is Coolgap?

CoolGap is the most recent disruption in the field of inductive components heat dissipation. CoolGap concept can be applied to bobbins (coil former) for wire wound magnetic devices which are refrigerated by a non-electro-conductive coolant liquid. This bobbin appears to be particularly useful for magnetic components used in on board power converters for electric and hybrid vehicles that make use of customized magnetic power components to increase power density.

Why CoolGap Technology?

1. Improved thermal performance: Coolgap technology increases heat transfer rate, optimizing component thermal management, reducing the use of potting compounds and aluminum housings.
2. Lower weight: Safely cooled higher power density components leads to lower part weight. In magnetic components, weight can be reduced up to 50% considering fixed max. temperature.
3. Higher efficiency: Lower weight reduces energy consumption while lower volume increase energy storage capacity, killing two birds with one stone.
4. Sustainability: Lower part weight leads to lower raw material usage, while higher efficiency reduces energy consumption, double positive impact on sustainability.
5. Lower cost: Lighter and smaller parts help reduce raw material usage of the component itself and the housing where they are placed. For example, smaller transformers would also lead to smaller converters, reducing overall cost.
6. Safety: Improved thermal management reduces safety issues regarding overheating, battery thermal runaway, etc.

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TECHNOLOGIES

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INNOVATIVE

CoolGap coil formers

Coolgap coil formers are designed to maximize inductive magnetic components heat evacuation by an internal duct that is connected to the vehicle cooling system. There are different sizes available depending on the magnetic core used, the heat losses that must be dissipated and the coolant pressure drop through the part depending on the coolant volume flow rate.

High thermal conductivity coil formers

COOLMAGPLAST TM product family consist of thermally conductive, electrically non-conductive PA6 based flame retardant grade coil formers. 2 W/mK thermal conductivity in the coil former’s plastic provides the ability to meet demanding engineering requirements in many applications more cost-effectively than other materials including metals, ceramics, and other plastics. There are both standardized and customized coil formers available.

Reduced of temperature
Reduced weight
Reduced volume
Overall system efficiency

A Cooling Breakthrough

Many tests were done to verify the positive impact of CoolGap in the part temperature. A transformer and choke part was tested at different duty points. At 2L duty point the standard part reached 55ºC. The part temperature dropped to 31ºC when using CoolGap with 25ºC coolant (44% reduction). At 1L duty point the Coolgap part with 25ºC coolant reached a 37ºC lower temperature than the standard part. At 1L duty point the standard part reached 110ºC. The part temperature dropped to 94ºC when using CoolGap with 25ºC coolant (14.5% reduction).

Benefits

Heat Removal

Volume Reduction

Multiple Designs

Diverse uses

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