Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system may include an inductor assembly, a flange extending around a periphery of the inductor assembly, and a sealing wall having an outer periphery and a sealing surface forming a seal with the flange. A bottom surface may extend from the outer periphery and a cavity may be defined by the outer periphery, the bottom surface, and the inductor assembly. A coolant inlet may be configured to provide coolant to the cavity. The inductor assembly may include at least one conductive coil wrapped around a core. A bottom portion, optionally only the bottom portion, of the coil may be disposed within the cavity and configured to be directly contacted and cooled by the coolant (e.g., ATF).

Abstract: A vehicle is provided with a transmission and an inductor assembly that is mounted within a chamber of the transmission. The inductor assembly includes a coil, a core and an insulator having first and second portions that are oriented toward each other. Each portion includes a base, a support extending from the base, and a spool extending transversely from the support to engage the other portion. Each spool includes an external surface for supporting the coil and a cavity extending therethrough for receiving the core.

Abstract: A vehicle is provided with a transmission having a chamber with fluid therein. The vehicle includes a core and a conductor that are mounted within the chamber. The core includes a pair of elements that are oriented toward each other along a longitudinal axis. Each element includes a base with a post and at least two projections extending longitudinally from the base. The conductor is disposed over the posts and is configured to receive the fluid through an opening formed between adjacent projections.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle may include a transmission case including a coolant inlet and an inductor assembly having a flange extending around a periphery thereof. A thermally conductive cover having a sealing surface may form a seal with the flange. A cavity may be defined between the cover and the inductor assembly and configured to receive coolant from the coolant inlet. A thermal interface material (TIM) may be in contact with a surface of the cover and a surface of the transmission case. The TIM may be a solid or a paste-like substance. If the TIM is solid, it may be in a state of compression between a bottom surface of the cover and the surface of the transmission case. The TIM may transfer heat from coolant in the cavity to the transmission case while the coolant is not being circulated.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system, may include an inductor assembly, a flange extending around a periphery of the inductor assembly, an inductor cover having a sealing surface forming a seal with the flange, a cavity defined by the inductor cover and the inductor assembly, and a first opening defined in the inductor cover configured to provide coolant to the cavity. The flange may include a first recess defined therein that communicates with the first opening and is configured to receive coolant through the first opening and provide it to the cavity. A portion of the cover including the first opening may be configured to form a seal with a coolant inlet of a vehicle transmission case such that coolant is configured to flow through the coolant inlet, through the first opening, into the first recess, and into the cavity.

Abstract: A vehicle inductor assembly includes an inductor, a thermal plate, an emitter, and a controller. The inductor is secured within a housing. The thermal plate supports the inductor and includes a channel having a flexible wall with actionable particles. The emitter is located adjacent the channel. The controller is programmed to activate the emitter to impart a force upon the particles to move the wall such that a cross-sectional area of the channel is adjusted to influence a flow rate of coolant flowing therethrough. The wall may be a membrane partially secured to an interior of the channel and include the actionable particles. The actionable particles may be one of dielectric and magnetic particles and the emitter may selectively output one of a voltage, an electric field, or a magnetic field to move the dielectric or magnetic particles such that the membrane moves to adjust the cross-sectional area of the channel to influence a flow rate of coolant flowing therethrough.

Abstract: A vehicle is provided with a transmission and an inductor assembly that is mounted within a chamber of the transmission. The inductor assembly includes a coil, a core and an insulator having first and second portions that are oriented toward each other. Each portion includes a base, a support extending from the base, and a spool extending transversely from the support to engage the other portion. Each spool includes an external surface for supporting the coil and a cavity extending therethrough for receiving the core.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system, may include an inductor assembly, a flange extending around a periphery of the inductor assembly, an inductor cover having a sealing surface forming a seal with the flange, a cavity defined by the inductor cover and the inductor assembly, and a first opening defined in the inductor cover configured to provide coolant to the cavity. The flange may include a first recess defined therein that communicates with the first opening and is configured to receive coolant through the first opening and provide it to the cavity. A portion of the cover including the first opening may be configured to form a seal with a coolant inlet of a vehicle transmission case such that coolant is configured to flow through the coolant inlet, through the first opening, into the first recess, and into the cavity.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system may include an inductor assembly secured to a vehicle transmission case and including a core and a conductive coil wrapped around the core. A thermal interface material (TIM) may be spaced apart from the core and may contact a bottom portion of the conductive coil and a surface of the transmission case. The TIM may be configured to transfer heat from the conductive coil to the transmission case. The TIM may be a compressed solid thermal interface material. The TIM may be in contact with at least 85% of a projected surface area of the bottom portion of the conductive coil. The TIM may passively cool the conductive coil(s) of the inductor assembly by transferring heat from the coils to a vehicle transmission case, which may act as a heat sink.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system may include an inductor assembly, a flange extending around a periphery of the inductor assembly, and a sealing wall having an outer periphery and a sealing surface forming a seal with the flange. A bottom surface may extend from the outer periphery and a cavity may be defined by the outer periphery, the bottom surface, and the inductor assembly. A coolant inlet may be configured to provide coolant to the cavity. The inductor assembly may include at least one conductive coil wrapped around a core. A bottom portion, optionally only the bottom portion, of the coil may be disposed within the cavity and configured to be directly contacted and cooled by the coolant (e.g., ATF).

Abstract: Inductor cooling systems and methods are disclosed. A vehicle may include a transmission case including a coolant inlet and an inductor assembly having a flange extending around a periphery thereof. A thermally conductive cover having a sealing surface may form a seal with the flange. A cavity may be defined between the cover and the inductor assembly and configured to receive coolant from the coolant inlet. A thermal interface material (TIM) may be in contact with a surface of the cover and a surface of the transmission case. The TIM may be a solid or a paste-like substance. If the TIM is solid, it may be in a state of compression between a bottom surface of the cover and the surface of the transmission case. The TIM may transfer heat from coolant in the cavity to the transmission case while the coolant is not being circulated.

Abstract: A vehicle inductor assembly includes an inductor, a thermal plate, an emitter, and a controller. The inductor is secured within a housing. The thermal plate supports the inductor and includes a channel having a flexible wall with actionable particles. The emitter is located adjacent the channel. The controller is programmed to activate the emitter to impart a force upon the particles to move the wall such that a cross-sectional area of the channel is adjusted to influence a flow rate of coolant flowing therethrough. The wall may be a membrane partially secured to an interior of the channel and include the actionable particles. The actionable particles may be one of dielectric and magnetic particles and the emitter may selectively output one of a voltage, an electric field, or a magnetic field to move the dielectric or magnetic particles such that the membrane moves to adjust the cross-sectional area of the channel to influence a flow rate of coolant flowing therethrough.

Abstract: A vehicle is provided with a transmission and an inductor assembly that is mounted within a chamber of the transmission. The inductor assembly includes a coil, a core and an insulator having first and second portions that are oriented toward each other. Each portion includes a base, a support extending from the base, and a spool extending transversely from the support to engage the other portion. Each spool includes an external surface for supporting the coil and a cavity extending therethrough for receiving the core.

Abstract: A power module assembly includes opposing end caps collectively having coolant ports and a row of cards that each have a major side defining a projection extending across the card. A side panel extends between the end caps such that the panel and row define a channel in fluid communication with the ports and configured to convey coolant directly across the cards. The side panel defines a groove that receives the projections.

Abstract: A power module assembly includes opposing end caps collectively having coolant ports and a row of cards that each have a major side defining a projection extending across the card. A side panel extends between the end caps such that the panel and row define a channel in fluid communication with the ports and configured to convey coolant directly across the cards. The side panel defines a groove that receives the projections.

Abstract: A vehicle electrical power system includes a variable voltage converter. The variable voltage converter includes an inductor assembly having a housing that defines a chamber containing dielectric fluid. An inductor is disposed within the chamber and is in contact with the fluid. The power system also includes a pump configured to circulate the dielectric fluid to cool the inductor.

Abstract: A vehicle is provided with a transmission and an inductor assembly that is mounted within a chamber of the transmission. The inductor assembly includes a coil, a core and an insulator having first and second portions that are oriented toward each other. Each portion includes a base, a support extending from the base, and a spool extending transversely from the support to engage the other portion. Each spool includes an external surface for supporting the coil and a cavity extending therethrough for receiving the core.

Abstract: A vehicle electrical power system includes a variable voltage converter. The variable voltage converter includes an inductor assembly having a housing that defines a chamber containing dielectric fluid. An inductor is disposed within the chamber and is in contact with the fluid. The power system also includes a pump configured to circulate the dielectric fluid to cool the inductor.

Abstract: A vehicle is provided with a transmission that defines a chamber, and a coil that is mounted within the chamber. The coil defines a cavity. The vehicle also includes a core having at least two projections that are spaced radially outward of the coil and angularly spaced apart from each other to define openings therebetween. The core also includes first and second ends that are interconnected by a post that extends through the cavity.

Abstract: A vehicle is provided with a transmission having a chamber with fluid therein. The vehicle includes a core and a conductor that are mounted within the chamber. The core includes a pair of elements that are oriented toward each other along a longitudinal axis. Each element includes a base with a post and at least two projections extending longitudinally from the base. The conductor is disposed over the posts and is configured to receive the fluid through an opening formed between adjacent projections.