Coil Core Heat-Dissipating Plate Layout to Limit Eddy Current Loss
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Solution Overview
Problem
The existing coil devices with radiator plates attached to cores to improve heat radiation properties suffer from increased loss and reduced efficiency due to magnetic saturation when a gap is provided between the cores.
Innovation Solution
A coil device design where a heat-dissipating plate is attached to one core, allowing the gap side portion between the cores to be at least partly free, preventing magnetic field influence and eddy current generation, while enhancing heat transfer and dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a radiator plate is attached to cover the first core and the second core, then heat radiation properties are improved, but loss increases and efficiency decreases when a gap is provided between the cores
Solution Approach 1:
The heat-dissipating plate is designed with differentiated coverage: it covers the base portion and outer leg portions of the first core for effective heat dissipation, while intentionally leaving the gap side portion exposed. This local differentiation allows the plate to perform its heat dissipation function without interfering with the magnetic field in the gap region, thereby avoiding eddy current losses while maintaining thermal management effectiveness.
2Temperature
If a radiator plate is attached to cover the cores, then heat-dissipation ability is improved, but magnetic field influence increases causing eddy current generation
Solution Approach 1:
The gap side portion is extracted from the coverage area of the heat-dissipating plate. By deliberately not covering this specific region, the design removes the source of magnetic field interference and eddy current generation, while the remaining covered portions continue to provide effective heat dissipation from the core surfaces.
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 reduces loss and improves efficiency by minimizing the magnetic field's impact on the heat-dissipating plate and effectively transfers heat, thereby enhancing the coil device's heat-dissipation ability.
Implementation Method 1
as heat of the first core is transferred to the first heat-dissipating plate, heat-dissipation ability of the coil device can be improved
Implementation Method 2
a magnetic field generated at the gap side portion does not readily influence the first heat-dissipating plate to not readily generate an eddy current at the first heat-dissipating plate
Data Source
AI summary
A coil device comprises a coil; a bobbin provided with the coil; a first core and a second core attached to the bobbin so as to face each other; and a first heat-dissipating plate attached to the first core. The first core comprises a first base portion and a first outer leg portion protruding from the first base portion and facing the second core with a gap therebetween. The gap has a gap side portion between a first side surface of the first outer leg portion and a second side surface of the second core. The first heat-dissipating plate covers at least the first base portion or the first outer leg portion so that the gap side portion is at least partly free.