A practical liquid-cooling design method for magnetic components of EMI filter in high power motor drives

This paper focuses on the liquid-cooling method of power inductors in electromagnetic interference (EMI) filters for high power motor drive application. A literature study on magnetic cooling methods with encapsulation, potting and liquid-cooled cold plate is carried out. An empirical evaluation method for potting effectiveness is proposed and validated with prototype encapsulation and example potting materials. One simplified experiment-based thermal modeling method for inductors is also developed with the purpose of avoiding time-consuming finite element simulation. Based on the potting evaluation method and simplified thermal modeling, one comprehensive design procedure is summarized.