Reactor Coil and Magnetic Core Design for Low Height and Energy Loss
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Solution Overview
Problem
There is a demand for reactors with low installation height and low energy loss, while maintaining excellent heat dissipation properties, as reducing reactor height can lead to increased energy loss due to leakage magnetic flux interactions.
Innovation Solution
A coil with tubular winding portions featuring recessed portions and a magnetic core with inner and side leg portions that include recessed and projecting features, allowing for a compact design with exposed areas for heat dissipation and reduced leakage magnetic flux, are used to construct a reactor with low installation height and energy loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the installation height is reduced by changing the end face shape to a horizontally long rectangular shape, then the installation height is reduced, but the energy loss increases due to leakage magnetic flux interaction
Solution Approach 1:
The magnetic core is divided into multiple segments including an inner leg, two side legs, and two connection portions. This segmentation allows the magnetic core to conform to the horizontally long rectangular shape while maintaining proper magnetic flux paths, reducing leakage flux interaction and energy loss despite the reduced installation height
Solution Approach 2:
The magnetic core structure is optimized with different configurations at different locations: the inner leg extends along the inner periphery, side legs are positioned at outer periphery, and connection portions couple these elements. This local optimization ensures that magnetic flux is properly contained throughout the horizontally elongated structure, preventing energy loss while achieving low installation height
2Loss of energy
If the side leg is interposed between the long side portion of the winding portion and the placement face, then the energy loss is reduced, but the installation height increases by the thickness of the side leg
Solution Approach 1:
The magnetic core structure transitions from a vertical arrangement to a horizontal arrangement by adopting a horizontally long rectangular shape. The side legs are positioned at the outer periphery in the horizontal dimension rather than extending vertically, allowing energy loss reduction without increasing installation height in the vertical dimension
3Temperature
If the winding portion is exposed without being covered by the magnetic core, then the heat dissipation properties are improved, but the magnetic flux interaction is reduced
Solution Approach 1:
The magnetic core provides localized magnetic flux containment at critical positions (inner leg along inner periphery, side legs at outer periphery, connection portions coupling these elements) while allowing other portions of the winding to remain exposed for heat dissipation. This selective coverage optimizes both magnetic efficiency and thermal management
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 configuration results in a reactor with reduced installation height, low energy loss, and enhanced heat dissipation properties, effectively addressing the challenge of minimizing height without increasing energy loss.
Implementation Method 1
A reactor is one type of component of a circuit for performing a voltage step-up operation or step-down operation
Implementation Method 2
a magnetic core formed by combining a pair of E-shaped divided cores
Implementation Method 3
heat from the coil is likely to be transferred to the installation target, and is likely to dissipate into the surrounding air from the upper face of the winding portion
Implementation Method 4
heat from the coil is likely to be transferred to the installation target, and is likely to dissipate into the surrounding air
Data Source
AI summary
A coil includes a tubular winding portion formed by winding a wire, wherein the winding portion includes two coil recessed portions that are provided such that recessed directions toward an inner space surrounded by an inner peripheral face of the winding portion are opposite to each other.