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.

The present invention provides an electromagnetic apparatus with heat sink structure, comprising: metal housing, the metal housing further comprises the upper housing and the lower housing to fix the components of the electromagnetic apparatus and store the energy of the electromagnetic apparatus during operation; the electrical coil is mounted on the coil shelf and is provided with numbers of primary windings and secondary windings; the heat conductive tube is arranged in the gap of the windings for conducting the heat generated by the electrical coil to the outside of the electromagnetic apparatus. Furthermore, the conducting wire is electrically coupled to the electrical coil and transmits the input voltage and output voltage during the operation of electromagnetic apparatus.

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.

An electro-magnetic coil with coolant permeability wound using insulated wire includes a plurality of radially arranged layers and a plurality of axially arranged turns of the insulated wire per layer, wherein the insulated wire has a plurality of sections along its length with different cross-sections for any pair of two adjacent sections that collectively form into axial and radial coolant channels as the wire is wound around a core.

A planar coil (10) of the present disclosure includes a base (1) including a first surface (1a), a metal layer (2) located on the first surface (1a) and including a through hole (2a) and a plurality of voids (3), and a first fixing tool (8) inserted through the through hole (2a) and fixing the metal layer (2) to the first surface (1a) side of the base (1).

Provided are a coil capable of further improvement in heat dissipation performance and a method for manufacturing the same. A coil includes a helical structure formed of a hollow flat conductor.

The invention comprises an apparatus, comprising: an inductor, the inductor comprising: an electrical turn about an inductor core, the inductor core comprising a ring shape; the electrical turn comprising a first width at a first radial distance from a center of the inductor core and a second width at a second radial distance from the center, the second width at least ten percent larger than the first width. Optionally and preferably, the electrical turn comprises: a first cast element and a second cast element and a mechanical connection connecting the first cast element to the second cast element, such as an aluminum weld.

The present disclosure describes an induction charging device for a partially or fully electrically operated motor vehicle. The induction charging device includes at least one charging coil and a temperature-control assembly including a fluid pipe for a liquid fluid. The charging coil is inductively couplable to a primary coil such that a battery can be inductively charged in the motor vehicle. The charging coil is heat-transmittingly connected to the fluid pipe such that the waste heat from the charging coil can be transmitted to the fluid. The induction charging device further includes a metal shielding plate for shielding electromagnetic field emissions, and a ferrite assembly for directing an electromagnetic alternating field. The charging coil is arranged in the fluid pipe such that the fluid can flow around it on all sides. The charging coil is secured in the fluid pipe directly or via a retaining device.

The present disclosure disclosed a wireless charging module manufacturing method. The method includes the following steps: forming a first heat dissipating layer on a surface of a coil; and securing a magnetic shield part to the surface of the coil away from the first heat dissipating layer. A wireless charging module is manufactured by the method. By completely cover the coil with the first heat dissipating layer in the present disclosure, the first heat dissipating layer possesses excellent heat radiation, effectively improving the heat dissipation of the coil. The thickness of the first heat dissipating layer is controllable. Therefore, an effective and highly stable heat dissipating performance can be provided without increasing the thickness and cost of the wireless charging module.