Heat pipe cooling of power processing magnetics
The constant demand for increased power and reduced mass has raised the internal temperature of conventionally cooled power magnetics toward the upper limit of acceptability. The conflicting demands of electrical isolation, mechanical integrity, and thermal conductivity preclude significant further advancements using conventional approaches. However, the size and mass of multikilowatt power processing systems may be further reduced by the incorporation of heat pipe cooling directly into the power magnetics. Additionally, by maintaining lower more constant temperatures, the life and reliability of the magnetic devices will be improved. A heat pipe cooled transformer and input filter have been developed for the 2.4 kW beam supply of a 30-cm ion thruster system. This development yielded a mass reduction of 40% (1.76 kg) and lower mean winding temperature (20 C lower). While these improvements are significant, preliminary designs predict even greater benefits to be realized at higher power. This paper presents the design details along with the results of thermal vacuum operation and the component performance in a 3 kW breadboard power processor.