The invention comprises a method for forming an inductor, comprising the steps of: providing an inductor core and fastening at least ten sections of a winding together to form a winding, the winding comprising a formed wound shape about the inductor core. Optionally and preferably the step of fastening repeats steps of joining a member of a first set of winding parts to an element of a second set of winding parts, where the two sets of winding parts have different cast or formed shapes.

A stationary induction charging station for a vehicle is disclosed. The stationary induction charging station includes an induction charging device, an energy transfer module for contact-free energy transfer, and an electronic unit. According to an example, the energy transfer module and the electronic unit are spatially combined.

A stationary induction charging station for a vehicle is disclosed. The stationary induction charging station includes an induction charging device, an energy transfer module for contact-free energy transfer, and an electronic unit. According to an example, the energy transfer module and the electronic unit are spatially combined.

An inductor includes a bobbin defining a cavity, coils wound around the bobbin, and a plug inserted into the cavity. The plug and bobbin define a first fluid path between an inlet and the cavity. The plug is also arranged to choke flow of fluid through the first fluid path.

An inductor includes a bobbin defining a cavity, coils wound around the bobbin, and a plug inserted into the cavity. The plug and bobbin define a first fluid path between an inlet and the cavity. The plug is also arranged to choke flow of fluid through the first fluid path.

The invention comprises a method of: providing an inductor core, placing a winding guide within an inch of the inductor core, positioning a first turn element with the winding guide, positioning a second turn element with the winding guide, and mechanically coupling the first turn element to the second turn element to form at least a part of a winding, the winding forming a wrapped shape about the inductor core. Optionally and preferably, turn elements are subsequently joined, mechanically coupled, and/or welded together to form sections of the winding.

A magnetic element. In some embodiments, the magnetic element includes a first electrically conductive coil, having a first annular surface and a second annular surface; a second electrically conductive coil, having a first annular surface and a second annular surface; and a spacer between the first electrically conductive coil and the second electrically conductive coil; a fluid inlet; and a fluid outlet. The spacer may have a first face, the first face being separated from the first annular surface of the first electrically conductive coil by a first gap; and a fluid path may extend from the fluid inlet to the fluid outlet through the first gap.

A thermal management includes an inductor, a housing in thermal communication with the inductor, the housing defining a wall, and a conductor. The conductor has a greater heat transfer rate than the wall and is positioned within a groove and/or an aperture formed in the wall. The conductor is configured to transfer heat through the wall more efficiently than if the conductor were not present. A method of manufacturing a thermal management system includes forming a housing by additive manufacturing. The housing defines a wall having at least one of a groove and an aperture defined therein. The method includes positioning a conductor in at least one of the groove and the aperture. The conductor has a greater heat transfer rate than the wall. The method includes positioning an inductor into thermal communication with the housing.

A thermal management includes an inductor, a housing in thermal communication with the inductor, the housing defining a wall, and a conductor. The conductor has a greater heat transfer rate than the wall and is positioned within a groove and/or an aperture formed in the wall. The conductor is configured to transfer heat through the wall more efficiently than if the conductor were not present. A method of manufacturing a thermal management system includes forming a housing by additive manufacturing. The housing defines a wall having at least one of a groove and an aperture defined therein. The method includes positioning a conductor in at least one of the groove and the aperture. The conductor has a greater heat transfer rate than the wall. The method includes positioning an inductor into thermal communication with the housing.

A vehicle, an inductor assembly for power electronics in a vehicle, and a method of providing and cooling an inductor assembly are provided. According to one example, the vehicle is provided with an inductor assembly in a vehicle electrical system with a variable voltage converter (VVC). The inductor assembly includes a core formed from a plurality of core segments spaced apart from one another to define gaps therebetween, with each of the plurality of core segments forming an internal fluid passage extending therethrough. The inductor assembly has a winding surrounding at least one of the plurality of core segments. A fluid system is connected to the core to provide pressurized fluid to the fluid passages of the plurality of core segments to circulate fluid through the core of the inductor assembly.