Compressible Graphite Sheet Cooling for Reactor Thermal Management
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Solution Overview
Problem
Conventional reactor devices used in electric and hybrid vehicles face inefficiencies in heat dissipation due to the limited thermal conductivity of gel sheets, which can lead to decreased cooling performance over time as the gel sheets are compressed and their thermal conductivity is reduced by repetitive heat generation and cooling cycles.
Innovation Solution
A reactor device configuration that includes a coil, a magnetic core, a case, a cooling plate, an insulating sheet, and a compressible graphite sheet, where the graphite sheet is compressed between the coil and the cooling plate, enhancing thermal conductivity and preventing graphite powder scattering, while the insulating sheet deforms to increase contact area and reduce thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gel sheet is used for cooling the reactor, then the reactor can be cooled, but the thermal conductivity decreases over time due to compression and repetitive heat cycles
Solution Approach 1:
The patent changes the material parameter from gel sheet to compressible graphite sheet, which maintains thermal conductivity under compression and repetitive heat cycles, thereby resolving the degradation issue while preserving cooling performance
Solution Approach 2:
The patent uses a composite structure combining insulating sheet and compressible graphite sheet together, where the graphite sheet provides stable thermal conduction path while the insulating sheet provides electrical insulation, achieving both reliable cooling and maintained thermal conductivity
2Reliability
If the cooling plate is fixed to the case with screws, then the cooling plate is secured, but the coil and cooling plate need effective thermal contact
Solution Approach 1:
The patent introduces compressible graphite sheet as an intermediary between the coil and cooling plate that serves dual functions: providing electrical insulation while maintaining low thermal resistance through compression, thus resolving the conflict between secure fixing and effective thermal contact
3Object-affected harmful factors
If an insulating sheet is disposed between the coil and cooling plate, then electrical insulation is provided, but thermal contact area needs to be maximized
Solution Approach 1:
The patent applies different material properties to different layers: the insulating sheet provides electrical insulation where needed, while the compressible graphite sheet provides thermal conduction in the same interface region, achieving both electrical insulation and thermal contact through localized material differentiation
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
The configuration achieves higher cooling performance and reliability by improving thermal conductivity and maintaining efficient heat dissipation, as the compressible graphite sheet effectively transfers heat to the cooling plate, and the insulating sheet's deformation enhances contact with the coil, reducing thermal resistance.
Implementation Method 1
the compressible graphite sheet effectively transfers heat to the cooling plate
Implementation Method 2
the insulating sheet deforms to increase contact area and reduce thermal resistance
Implementation Method 3
the reactors are each connected to a cooling plate with a heat-dissipation member, such as a gel sheet, thereby cooling the reactors
Data Source
AI summary
A reactor device includes a coil, a magnetic core having the coil thereon, a case accommodating the coil and the magnetic core, a cooling plate fixed to the case, an insulating sheet disposed between the coil and the cooling plate, a compressible graphite sheet disposed between the coil and the cooling plate, and a screw to fix the cooling plate to the case. The case has a screw hole and an opening provided therein. The screw passes through the screw hole to fix the cooling plate to the case. The coil contacts the insulating sheet through the opening of the case. The graphite sheet contacts the cooling plate. The reactor has high cooling performance and reliability.