Segmented Magnetic Core Structure for Eddy Loss and Thermal Stress
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Solution Overview
Problem
Magnetic components in on-board chargers for electric vehicles generate excessive heat due to operational losses, leading to thermal stress and potential irreversible damage, as heat dissipation is inefficient and uneven, particularly in the inner leg of the transformer core.
Innovation Solution
A magnetic component design featuring a core with an inner leg divided into separate portions to reduce eddy current losses, combined with a heat dissipating member and thermal conductive filler to enhance heat transfer and dissipation, and a plastic casing for improved insulation and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the inner leg is divided into multiple separated portions, then eddy current loss is reduced, but structural complexity increases
Solution Approach 1:
The inner leg of the core is divided into multiple separated portions along its length direction. This segmentation reduces the cross-sectional area perpendicular to the magnetic flux direction, thereby reducing eddy current loss. The separated portions are positioned to maintain necessary magnetic flux paths while breaking up continuous conductive paths that would otherwise support large eddy currents.
2Temperature
If thermal conductive filler is used to cover the entire coil, then heat dissipation is improved, but material cost and complexity increase
Solution Approach 1:
The thermal conductive filler is applied selectively to specific regions where heat dissipation is most critical, such as areas with highest temperature or poorest natural convection. This localized application maintains effective thermal management while reducing material usage and structural complexity compared to complete coil coverage.
3Temperature
If the inner leg is separated from the upper inner surface, then heat dissipation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The separation between the inner leg and upper inner surface is designed with predetermined gap dimensions that are accounted for in the manufacturing process. This preliminary design of the gap allows for controlled thermal expansion and contraction while maintaining consistent heat dissipation performance across production batches.
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 design effectively reduces thermal stress and heat-related losses by improving heat dissipation efficiency, extending the lifespan of magnetic components and maintaining high bonding forces, while also offering cost-effective and efficient heat management.
Implementation Method 1
the thermal conductive filler is filled at the opening of the side surface and covers a part of the at least one coil rather than wholly covering the at least one coil
Implementation Method 2
The heat dissipating member is disposed on the core. The heat dissipating member is in contact with a top surface and a side surface of the core
Implementation Method 3
the inner leg at least partially divided into a plurality of separated portions along the length direction of the inner leg can reduce the cross-sectional area of the inner leg perpendicular to the magnetic flux direction, so as to reduce the eddy current loss of the core
Data Source
AI summary
A magnetic component includes a core and at least one coil. The core includes at least one outer leg and an inner leg. The inner leg is separated from an upper inner surface of the core. The inner leg is at least partially divided into a plurality of separated portions along a length direction of the inner leg. The at least one coil is wound around the inner leg.