Magnetic Coil Housing With 3D Heat Dissipation Pathways
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Solution Overview
Problem
In-vehicle chargers and power conversion devices face challenges in efficiently dissipating heat from magnetic components like inductors and transformers due to large current and high voltage, necessitating a downsized design to accommodate limited vehicle space.
Innovation Solution
A magnetic component design featuring a box-shaped metal case with thermal conductivity, filled with a potting material, which acts as a heat dissipation pathway by thermally connecting the component main body to a heat dissipation part through a top surface and side surfaces, utilizing thermal conductance to transfer heat to a cooling surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a magnetic component is downsized to accommodate limited vehicle space, then the device size is reduced, but heat dissipation efficiency deteriorates
Solution Approach 1:
The patent transitions from conventional planar heat dissipation to three-dimensional heat dissipation by configuring the metal case with multiple heat dissipation surfaces including side surfaces and end surfaces. This spatial arrangement creates multiple thermal conduction pathways in different dimensions, allowing efficient heat removal from the magnetic component while maintaining a compact overall size.
Solution Approach 2:
The patent introduces a heat dissipation plate as an intermediary thermal conduction element between the magnetic component and the metal case. This plate enhances thermal coupling and provides an additional heat transfer pathway, improving heat dissipation efficiency without increasing the external dimensions of the magnetic component.
2Temperature
If a metal case with heat dissipation structure is added to improve heat dissipation, then heat dissipation efficiency is improved, but device complexity increases
Solution Approach 1:
The metal case is designed to serve multiple functions simultaneously: it provides mechanical protection for the magnetic component, acts as a heat dissipation structure through its thermally conductive material and configured surfaces, and serves as a mounting structure. This multi-functionality improves heat dissipation while avoiding the need for separate dedicated heat sink components, thereby limiting the increase in structural complexity.
Solution Approach 2:
The patent combines the heat dissipation function with the protective casing by making the metal case itself the heat dissipation structure. The heat dissipation surfaces are integrated into the case geometry rather than being separate attachments, merging protection and thermal management into a single unified structure.
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 dissipates heat from the magnetic components, enabling a compact size suitable for vehicle installations while maintaining efficient thermal management.
Implementation Method 1
The box-shaped member functions as a heat dissipation pathway through which heat is transported from the component main body to the heat dissipation part via the top surface by thermal conductance
Implementation Method 2
The potting material having thermal conductivity is filled into the box-shaped member from the opening part
Data Source
AI summary
A magnetic component includes a component main body from which heat is to be dissipated, a box-shaped member whose one face is opened, and a potting material having thermal conductivity and being filled into the box-shaped member. The box-shaped member includes a plate-like member having thermal conductivity. The box-shaped member includes an opening part, a top surface facing the opening part, side surfaces extending from the top surface to the opening part, and a heat dissipation part provided at an end on a side of the opening part of the side surface. The top surface of the box-shaped member is thermally connected to a first principal surface of the component main body. The box-shaped member functions as a heat dissipation pathway through which heat is transported from the component main body to the heat dissipation part via the top surface by thermal conductance.