A common mode choke apparatus includes a first bus bar forming a first plurality of loops about a first segment of a ferrite core, the first bus bar having a plurality of first upper surfaces, and a second bus bar forming a second plurality of loops about a second segment of the ferrite core, the second bus bar having a plurality of second upper surfaces.

A shunt reactor includes a primary winding and a steel core is. The steel core includes a bottom yoke, a top yoke, a first core limb, a second core limb, and a main limb. The first core limb, the second core limb and the main limb are arranged in parallel and in between the top yoke and the bottom yoke to form a support for a magnetic flux through the steel core. The primary winding is wound around the main limb. The shunt reactor further includes an auxiliary winding wound around the bottom yoke, top yoke, first core limb, or second core limb, and is configured to generate auxiliary power. The primary and the auxiliary windings are electrically insulated from the steel core and from each other. A cooling fan is configured to be driven by the auxiliary power generated by the auxiliary winding.

A shunt reactor includes a primary winding and a steel core is. The steel core includes a bottom yoke, a top yoke, a first core limb, a second core limb, and a main limb. The first core limb, the second core limb and the main limb are arranged in parallel and in between the top yoke and the bottom yoke to form a support for a magnetic flux through the steel core. The primary winding is wound around the main limb. The shunt reactor further includes an auxiliary winding wound around the bottom yoke, top yoke, first core limb, or second core limb, and is configured to generate auxiliary power. The primary and the auxiliary windings are electrically insulated from the steel core and from each other. A cooling fan is configured to be driven by the auxiliary power generated by the auxiliary winding.

A cold plate and a method of manufacturing a cold plate involve a first side with a first surface, and a second side, opposite the first side, with a second surface opposite the first surface. The cold plate includes a flow channel formed between the first side and the second side, and a cavity integrally machined into the first surface of the first side. The cavity seats an inductor and is defined by an outer wall and a base with thicker sections and thinner sections such that even the thicker sections of the base are thinner than a thickness of the first surface.

A passive cooling topology and a manufacturing method are described for a transformer to achieve improved power density at a light weight. No fans or cooling liquids are required. Vertical planar faces are used for the central core element, the primary and secondary windings, the outer core element, and a finned heat sink. The primary flow for thermal cooling is radial, through the vertical planar faces. The transformer may be configured to float at the potential of a high voltage transmission line, leading to improved thermal characteristics. Eddy currents are reduced using repeating air gaps in the central core, and a continuously transposed cable comprising multiple strands per turn in the secondary winding. Air pockets in the windings are eliminated using a potting resin and vacuum pressure impregnation (VPI).

A passive cooling topology and a manufacturing method are described for a transformer to achieve improved power density at a light weight. No fans or cooling liquids are required. Vertical planar faces are used for the central core element, the primary and secondary windings, the outer core element, and a finned heat sink. The primary flow for thermal cooling is radial, through the vertical planar faces. The transformer may be configured to float at the potential of a high voltage transmission line, leading to improved thermal characteristics. Eddy currents are reduced using repeating air gaps in the central core, and a continuously transposed cable comprising multiple strands per turn in the secondary winding. Air pockets in the windings are eliminated using a potting resin and vacuum pressure impregnation (VPI).

An object is to improve a core and heat radiation properties from the coil, and to reduce the size of a transformer. In order to attain the object described above, a transformer includes a bobbin wound around with a coil, a columnar core center portion in which the bobbin is mounted, and a plurality of core leg portions joining both ends of the core center portion on the outside of the coil. The size of the core leg portion is larger than the size of the other core leg portions, and the core leg portion includes a flat outer circumferential surface approximately parallel to a surface which is tangent to an outer circumferential side surface of the coil. The transformer is disposed in a housing such that the outer circumferential surface of the core leg portion is tangent to a floor surface of the housing.

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof. Each PCB panel comprises discrete, PCB radial segments that are mechanically and electrically coupled together to form the respective PCB panels.

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof. Each PCB panel comprises discrete, PCB radial segments that are mechanically and electrically coupled together to form the respective PCB panels.

An magnetic component structure with thermal conductive filler is provided in the present invention, including an upper magnetic core, a lower magnetic core combining with the upper magnetic core to form a casing with a front opening and a rear opening, and a coil mounted in the casing, where two terminals of the coil extend outwardly from the front opening, and a thermal conductive filler filling between the casing and the coil in the casing.