Magnetic Component Heat Dissipation Layout for Fast EV Charging
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Solution Overview
Problem
Magnetic components in on-board chargers for electric vehicles experience excessive heat generation due to operational losses, leading to thermal stress and potential irreversible damage, as heat does not dissipate effectively, especially in high-voltage applications.
Innovation Solution
A magnetic component design featuring a core with separated inner legs to reduce eddy current loss, combined with heat dissipating members and thermal conductive fillers to enhance heat transfer and dissipation, and a plastic casing for improved insulation and heat management, allowing for efficient heat dissipation without compromising structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the operating power is increased to meet fast charging demand, then the charging speed is improved, but the heat generated by electronic components increases
Solution Approach 1:
The core is divided into multiple separate portions (first core portion and second core portion) instead of using a single continuous core. This segmentation reduces the eddy current path area, thereby reducing heat generation while maintaining the required power transmission capability for fast charging
Solution Approach 2:
A heat dissipating member is introduced as an intermediary between the core and the external environment. This member includes a heat dissipating surface that increases the heat transfer area, efficiently conducting heat away from the core and coils to maintain low operating temperatures during high-power fast charging
2Temperature
If the heat dissipating member extends to overlap with the inner leg for better heat transfer, then the heat dissipation efficiency is improved, but the manufacturing tolerance becomes more difficult to control
Solution Approach 1:
The heat dissipating member is designed with different extension characteristics in different regions: in the first and second joint regions, it extends to overlap with the outer legs for effective heat dissipation, while in the third joint region, it is positioned to avoid overlapping with the inner leg. This local differentiation allows the use of larger tolerance values without affecting heat dissipation performance
Solution Approach 2:
The heat dissipating member extends partially to overlap with certain core portions (outer legs) but deliberately avoids overlapping with other portions (inner leg). This partial extension strategy achieves sufficient heat dissipation while accommodating larger manufacturing tolerances, as the critical heat transfer paths are established through the overlapping regions with outer legs
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 buildup, enhancing the reliability and longevity of magnetic components by improving heat dissipation efficiency while maintaining structural integrity and cost-effectiveness.
Implementation Method 1
the heat of the inner leg can be transferred to the thermal conductive filler on the side or below through at least one of the first heat dissipating member and the second heat dissipating member, and then transferred to the heat dissipating surface below
Implementation Method 2
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, at least one coil, a first heat dissipating member and a second heat dissipating member. The core includes at least one outer leg and an inner leg. The at least one coil is wound around the inner leg. The first heat dissipating member is disposed on a first side and a top side of the core. The second heat dissipating member is disposed on a second side and the top side of the core. The first heat dissipating member and the second heat dissipating member have a first joint region, a second joint region and a third joint region on the top side. Projections of the first joint region and the second joint region do not overlap with the inner leg. A projection of at least one of the first heat dissipating member and the second heat dissipating member overlaps with the inner leg.