Electromagnetic Induction Coil Thermal Management via Air Gaps
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Solution Overview
Problem
Existing electromagnetic induction apparatuses face challenges in downsizing and efficient heat radiation due to increased thermal resistance from insulators and higher costs and size due to metal case housing with heat radiating resin.
Innovation Solution
The apparatus features coil portions with wiring patterns on a printed wiring board and metal members connected to these patterns, arranged side by side to form a coil body, allowing for efficient heat radiation and reduced thermal resistance without the need for a metal case filled with heat radiating resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If windings are wound in a multilayer structure with insulators between layers, then the degree of coupling between windings is improved and downsizing is enabled, but the heat radiating property degrades due to additional thermal resistance of insulators
Solution Approach 1:
The patent extracts the insulator material from between the windings, replacing it with air gaps. This removes the thermal resistance barrier while maintaining the multilayer winding structure's compactness and coupling benefits.
Solution Approach 2:
The patent introduces air gaps (porous structure) between the windings instead of solid insulator material. This porous configuration reduces thermal resistance to heat radiation while preserving the electrical insulation and mechanical structure needed for downsizing.
2Temperature
If a reactor main body is housed inside a metal case filled with heat radiating resin, then heat radiation from the coil is improved, but costs and size are inevitably increased
Solution Approach 1:
The patent removes the metal case and heat radiating resin entirely, replacing them with direct air-gap-based heat radiation pathways between windings and the core, eliminating the bulky housing while maintaining heat radiation efficiency.
Solution Approach 2:
The winding structure itself serves the dual function of electrical conduction and heat radiation through the air gaps, eliminating the need for separate heat radiation components like metal cases and resin fillers.
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 configuration enables reduced thermal resistance, downsizing, weight reduction, and cost savings while maintaining stable electrical characteristics and suppressing variations in inductance and loss.
Implementation Method 1
electromagnetic induction apparatus to be incorporated into, for example, a power converter
Implementation Method 2
heat can be efficiently radiated from the coil body to enable reduction of the thermal resistance
Data Source
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AI summary
In an electromagnetic induction apparatus, coil portions, each including a wiring pattern on a printed wiring board and a metal member having both end portions connected to the wiring pattern, are electrically connected to each other and arranged side by side to form a coil body. Therefore, for example, by mounting cooling means onto the printed wiring board, heat can be efficiently radiated from the coil body to enable reduction in thermal resistance.