Planar Coil Fixing Structure for Heat and Vibration Resistance
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Solution Overview
Problem
The challenge is to securely fix a planar coil within a power conversion device to prevent vibration and ensure stability, particularly in high-frequency applications where downsizing leads to increased heat generation and potential core damage.
Innovation Solution
A power conversion device design incorporating a laminated coil with a support structure, including first and second protruding members and fixing members, which sandwich the coil to securely attach it to the device, enhancing vibration resistance and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the switching frequency is increased to downsize the transformer, then the cross-sectional area of the core and turns of the coil are reduced, but heat generated from the coil increases due to larger electrical resistance and skin effect
Solution Approach 1:
A heat dissipation sheet is inserted as an intermediary between the coil and the core. This heat dissipation sheet has higher thermal conductivity than the core material, creating a thermal bridge that efficiently conducts heat away from the coil to the core and ultimately to the surrounding environment, thereby reducing coil temperature while maintaining the downsized transformer configuration
Solution Approach 2:
The thermal conductivity parameter of the interface between coil and core is changed by introducing a heat dissipation sheet with superior thermal conductivity properties. This parameter change enhances heat transfer efficiency, allowing the transformer to operate at high frequencies with reduced coil temperature despite the smaller cross-sectional area
2Volume of moving object
If a planar coil is used to downsize the transformer, then the transformer can be reduced in size, but the coil and cores may vibrate and be destroyed due to insufficient fixation
Solution Approach 1:
The coil, cores, and support structure are merged into a single integrated assembly through the fixing member. The fixing member combines the coil and cores together with the support, creating a unified structure that resists vibration and prevents individual components from moving or being damaged during operation
Solution Approach 2:
The fixing member is strategically positioned at specific locations where the coil contacts the support structure. This localized fixation approach provides sufficient vibration resistance at critical points while maintaining the overall downsized configuration of the transformer
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 solution effectively fixes the planar coil, reducing vibration-induced damage and heat-related issues, thereby improving the stability and performance of the power conversion device.
Implementation Method 1
a heat dissipation sheet is inserted between a coil wound in a planar shape and a core to reduce temperature increase of the coil
Implementation Method 2
skin effect occurs, in which current density is high at the surface of the conductor and decreases at a distance from the surface of the conductor. Therefore, as the frequency is higher, current intensively flows through the surface, so that AC resistance of the conductor increases and heat generated from the coil increases
Data Source
AI summary
In a coil device of a power conversion device, a laminated coil includes planar coils laminated on a surface of a support. A plurality of cores are spaced apart from each other and aligned in a longitudinal direction of the planar coils, and each core includes a portion around which the laminated coil is wound on the surface of the support. A first protruding member (is arranged between a pair of cores adjacent to each other with respect to a longitudinal direction and is fixed to the support. A first fixing member is arranged above the first protruding member. The laminated coil is sandwiched and fixed between the first fixing member and the first protruding member such that a first surface is in contact with the first protruding member and a second surface is in contact with the first fixing member.