Coolgap is the most recent disruption in the field of inductive component’s heat dissipation. It is an indirect cooling system based in ducts, where a non-electro-conductive coolant is fluing, removing the heat directly from the source. This system led us to increase significantly the power density of the parts carrying on multiple benefits for the field of magnetic power components.
CoolGap takes advantage of the optimized cooling circuit of the car by moving its coolant to the point of maximum loss generation of the magnetic component: the core gap. This allows heat dissipation to be direct from the source of the heat losses. In addition, the remaining heat to be transferred to the cool plate by conduction is greatly reduced and a new shorter path of low thermal resistivity is generated by introducing a cool surface internal to the bobbin itself.
- Ultra-Lightweight inductive components: The implementation of Coolgap leads to higher power losses dissipation. This means that current density can be increased in windings using thinner wires and magnetic flux density can be increased in cores making them smaller. This makes inductive components up to 50% lighter.
- Cost reduction: Smaller inductive components reduce the quantity of raw materials needed, reducing part cost.
- Extreme part temperature reduction: Inductive components implementing Coolgap technology have been tested to reduce temperature up to 100ºC under the same working conditions.
- Reduced core and winding losses due to lower operating temperature: Both winding Rdc and core losses increase with temperature. Coolgap helps reduce temperature, so as reducing power losses.
- Less quantity of thermal potting needed: Widespread current cooling solutions involve metal housings and thermal conductive potting compounds. Using Coolgap helps limiting the usage of this materials, reducing both weight and cost.
- Increased vehicle range: Lower vehicle weight means both lower power consumption and more available space for battery pack, what positively impacts vehicle range.
- Increased vehicle overall efficiency: Coolgap improves cooling system efficiency by reducing pressure drop through converter. This allows thermal engineers to use lower power consumption pumps.
- Reduced risk of part failure: If magnetic cores reach temperatures over Curie point, they demagnetize, causing part failure. In addition, part temperature gradients can cause ferrite cracks, creating undesired gaps and inductance drop.
