Flat Wire Coil Manufacturing for Reactor Heat Transfer
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Solution Overview
Problem
Reactor designs with flat wire coils face heat-transfer efficiency issues due to insulating film coverage, which can lead to short circuits when wire segments are tightly wound, compromising cooling performance.
Innovation Solution
A manufacturing method that forms thickened portions on the inner periphery of flat wire segments to maintain insulation between adjacent wire segments, preventing short circuits while enhancing heat transfer by ensuring appropriate clearance and using insulating films effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the flat wire is tightly wound in the pitch direction to improve space utilization, then the coil density increases, but adjacent wire segments contact each other causing short circuits
Solution Approach 1:
The insulating film is pre-formed on the flat wire surface before winding into a coil. This preliminary insulation layer prevents short circuits between adjacent wire segments when the coil is tightly wound, allowing high coil density without compromising electrical insulation reliability.
Solution Approach 2:
The insulating film provides localized insulation specifically at the regions where wire segments would contact during tight winding. This targeted insulation approach maintains electrical isolation only where needed for short circuit prevention, while allowing other areas to maintain close spacing for high density.
2Reliability
If the flat wire is covered with insulating film to prevent short circuits, then electrical insulation is improved, but heat-transfer efficiency from the coil to the cooler decreases
Solution Approach 1:
The insulating film is applied selectively only to portions of the flat wire that would contact adjacent wire segments during winding, rather than covering the entire wire surface. This localized insulation approach maintains electrical insulation where needed while leaving other surfaces exposed for efficient heat transfer to the cooler.
Solution Approach 2:
Instead of applying insulating film to the entire wire surface (excessive action), the film is applied only to the minimum necessary areas for preventing short circuits (partial action). This reduces the insulating material coverage to the essential minimum, thereby minimizing the impact on heat-transfer efficiency while still achieving reliable electrical insulation.
Data Source
AI summary
A method of manufacturing a reactor is provided. The reactor include: a coil including a wound flat wire, the flat wire being covered with an insulating film, and the coil having a flat surface; and a cooler facing the flat surface, in which the flat wire on an outer periphery side of the coil may be not covered with the insulating film at the flat surface, and the flat wire at the flat surface may include a plurality of wire segments lying in a pitch direction. The method may include pressing a rod against a short side of the plurality of wire segments to form at least one thickened portion in each of the plurality of wire segments, the thickened portion being a portion of the flat wire thickened in the pitch direction.