Integrated Transformer-Reactor Core Layout for Heat Dissipation
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Solution Overview
Problem
Existing power conversion devices for electric and hybrid automobiles, such as DC/DC converters, face challenges with size and cost due to the large number of magnetic parts like insulation transformers and smoothing reactors, which lead to increased heat generation and thermal resistance, resulting in a bulky and expensive system.
Innovation Solution
A power conversion device design that integrates the insulation transformer and smoothing reactor, with the primary-side coil and secondary-side coil wound on one side leg and the smoothing coil wound on another, sharing a common magnetic path on the center leg, reducing the number of parts and the required core size, and employing a planar type winding for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the insulation transformer and smoothing reactor are integrated with each other, then the number of parts is decreased and the device is downsized, but the projected area of the winding portion increases and heat dissipation becomes insufficient
Solution Approach 1:
The core is divided into multiple independent legs (first center leg, second center leg, first side leg, second side leg), allowing each leg to carry specific windings independently. This segmentation enables better thermal management by exposing different winding portions to cooling paths while maintaining the integrated structure's space-saving benefits.
Solution Approach 2:
The patent transitions from a planar arrangement to a three-dimensional core structure with multiple legs extending in different directions. This dimensional change allows windings to be arranged vertically and horizontally, increasing surface area for heat dissipation while maintaining a compact footprint.
2Volume of moving object
If a shell type smoothing reactor is used, then the structure is compact, but the windings cannot be sufficiently cooled and the device is upsized
Solution Approach 1:
The smoothing reactor windings are divided into multiple portions wound on different legs (first center leg and second center leg). This segmentation exposes different portions of the windings to different cooling paths, enabling sufficient cooling while maintaining a compact overall structure.
Solution Approach 2:
Different legs of the core are assigned different cooling characteristics. The first center leg has a first cooling path while the second center leg has a second cooling path, allowing each local region to be optimized for its specific thermal requirements while contributing to the overall compact design.
3Power
If four flat-plate-shaped windings are arranged between the center leg and side legs, then the required current can be achieved, but the core is upsized and cost increases
Solution Approach 1:
The four windings are distributed across four different legs instead of being concentrated in one location. The first and second insulation transformer windings are on the first side leg, while the first and second smoothing reactor windings are on the second side leg. This segmentation allows efficient current capacity while reducing the core's projected area and overall size.
Solution Approach 2:
Each leg of the core serves multiple functions: the first side leg carries both insulation transformer windings, and the second side leg carries both smoothing reactor windings. This multi-functionality reduces the total number of legs required, downsizing the core while maintaining the necessary current capacity.
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 decreases the size and cost of the power conversion device while maintaining efficient heat dissipation and reducing thermal resistance, leading to a more compact and economically viable solution.
Implementation Method 1
a primary-side coil and secondary-side coils magnetically coupled to the primary-side coil and wound on the core
Implementation Method 2
a smoothing coil electrically connected to the secondary-side coil and wound on the core
Data Source
AI summary
The power conversion device includes: a core; a primary-side coil wound on the core; a secondary-side coil wound on the core; and a smoothing coil wound on the core. The core has a first core, a second core, a center leg which makes connection between a center portion of the first core and a center portion of the second core, and a plurality of side legs which are away from the center leg and each of which makes connection between an end portion of the first core and an end portion of the second core. The primary-side coil and the secondary-side coil are wound on a first side leg among the side legs. The smoothing coil is wound on a second side leg among the side legs. A magnetic path common to the primary-side coil, the secondary-side coil, and the smoothing coil is formed on the center leg.