Air Conditioner Converter Layout for Inductor Heat Dissipation
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Solution Overview
Problem
Conventional converters for air conditioners generate excessive heat in inductors, leading to reduced efficiency and reliability due to inadequate heat dissipation, with existing heat sinks only addressing heat from switching elements and not inductors.
Innovation Solution
A converter design featuring a substrate with an inductor and switching element, where the inductor is partially inserted into a lead-in hole and a heat sink overlaps the inductor, supported by a heat transfer member to efficiently dissipate heat from both components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional heat sink is used to absorb heat from the switching element, then heat dissipation from the switching element is improved, but heat from the inductor cannot be dissipated effectively
Solution Approach 1:
The heat sink is designed to serve dual functions: it absorbs heat from the switching element through direct contact and simultaneously absorbs heat from the inductor by positioning the inductor within its heat dissipation field. This multi-functional design allows a single component to address thermal management for both heat-generating elements, resolving the contradiction between improving switching element cooling and enabling inductor heat dissipation.
2Quantity of substance
If the inductor is wound with a long coil to store current, then current storage capability is improved, but heat generation due to internal resistance increases
Solution Approach 1:
The patent positions the inductor within the heat sink's thermal field, converting the harmful heat generated by the inductor's internal resistance into a manageable thermal output. The heat sink absorbs this previously problematic heat, allowing the inductor to maintain its current storage capability with the long coil while the heat is simultaneously dissipated, thus converting a harmful effect into a controlled process.
3Productivity
If switching elements are turned on/off many times in short time to rectify AC to DC, then rectification efficiency is improved, but heat generation from switching elements increases
Solution Approach 1:
The patent merges the heat dissipation functions for both the switching element and inductor into a single integrated heat sink structure. By combining these thermal management functions, the system can handle the increased heat generation from high-frequency switching operations while maintaining rectification efficiency, as the unified heat sink manages thermal loads from both components simultaneously.
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 rapidly dissipates heat from the inverter, reduces converter size by utilizing space efficiently, and improves reliability by effectively managing heat from both the switching element and inductor.
Implementation Method 1
a heat sink for absorbing heat generated from the switching element by contacting the switching element
Implementation Method 2
discharge the generated heat to the outside
Implementation Method 3
an inductor disposed in one side of the substrate, and comprising a core and a coil wound around the core
Implementation Method 4
The switching element is a device that rectifies AC to DC by turning a switch on/off according to the command of a controller
Data Source
AI summary
A converter for an air conditioner includes a substrate, an inductor that is disposed in one side of the substrate and includes a core and a coil wound around the core, a switching element that is disposed in one side of the substrate and selectively controls a flow of a circuit, and a heat sink for absorbing heat generated from the switching element by contacting the switching element. A lead-in hole is formed in one side of the substrate, and at least a portion of the inductor is disposed in the lead-in hole, thereby quickly discharging the heat generated by the inverter and more efficiently using a space.