Segmented Air-Core Inductor Layout for High-Frequency Cooling
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Solution Overview
Problem
Inductors with flatwise-wound flat wires on cores face issues with heat dissipation, particularly at high frequency bands, leading to potential thermal runaway and damage to insulating coatings.
Innovation Solution
The inductor design features a plurality of coil parts formed by flatwise-winding flat wires in a radial direction with gaps between layers, arranged axially with a clearance for improved heat dissipation, and has an air-core configuration to minimize iron loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a core is used to increase self inductance, then the self inductance of the coil is improved, but heat dissipation deteriorates and temperature rise occurs
Solution Approach 1:
The coil is divided into multiple coil parts (first coil part, second coil part, etc.) arranged in series along the axial direction. This segmentation allows heat generated in each coil part to be dissipated independently through clearances between parts, preventing heat accumulation that would occur in a single continuous coil wrapped around a core.
Solution Approach 2:
The core is completely removed from the coil structure. Instead of wrapping the coil around a core, the invention uses multiple air-core coil parts arranged in series with clearances between them. This extraction of the core eliminates the heat conduction path from coil to core, allowing heat to be dissipated directly to the surrounding environment through the clearances.
2Use of energy by moving object
If flatwise-winding is used to increase density, then the self inductance is improved, but heat dissipation deteriorates
Solution Approach 1:
The densely wound flat coil is segmented into multiple coil parts with clearances between them. Each coil part maintains the high-density flatwise-winding structure for maximum inductance, while the clearances between parts provide heat dissipation pathways, resolving the contradiction between density and heat dissipation.
Solution Approach 2:
The invention transitions from a two-dimensional planar coil structure to a three-dimensional stacked structure with multiple coil parts arranged along the axial direction. The clearances between stacked parts introduce a new spatial dimension for heat dissipation while maintaining the high-density winding within each part.
3Productivity
If high frequency operation is used, then the productivity is improved, but iron loss increases and thermal runaway occurs
Solution Approach 1:
The core is removed from the structure, creating an air-core inductor. This eliminates ferromagnetic materials that cause hysteresis and eddy current losses at high frequencies. The multiple air-core coil parts maintain the required inductance value without the iron loss that would occur with a core, enabling high-frequency operation.
Solution Approach 2:
The invention changes the magnetic circuit parameter from ferromagnetic (core) to air. This parameter change eliminates frequency-dependent iron losses while maintaining the inductance function through the geometric arrangement of multiple coil parts, enabling stable high-frequency operation.
4Productivity
If high frequency operation is used, then the productivity is improved, but insulating coating damage occurs
Solution Approach 1:
By removing the core and using air-core coil parts with clearances, the maximum operating temperature is reduced. This lower temperature prevents thermal degradation and damage to the insulating coating on the flat wire, ensuring reliability at high frequencies.
Solution Approach 2:
The segmented coil structure with clearances provides multiple heat dissipation pathways, preventing heat accumulation that would otherwise raise the temperature high enough to damage the insulating coating during high-frequency operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances heat dissipation through airflow between coil parts, reduces iron loss with an air-core configuration, and maintains high precision, making it suitable for high-frequency applications while preventing thermal issues and insulating coating damage.
Implementation Method 1
there is provided a clearance between the plurality of coil parts, through which air flows, so that heat dissipation can be improved
Implementation Method 2
An inductor with a coil formed by flatwise-winding a flat wire has been conventionally proposed
Data Source
AI summary
An example inductor comprises multiple coil parts and each formed by flatwise-winding layers of turns of a flat wire arranged in a radial direction with gaps between each of the layers, and the multiple coil parts are arranged in an axial direction with a clearance. There is provided a clearance between the multiple coil parts, through which air flows, achieving improvement in heat dissipation.