Reactor Coil Layout With Inclined Case Walls for Uniform Cooling
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Solution Overview
Problem
Reactor designs with a vertical arrangement of winding portions in a small installation space face heat dissipation issues due to increased distance between winding portions and case walls, leading to uneven cooling and higher losses.
Innovation Solution
A reactor design with a case having inclined coil-facing surfaces and a second winding portion with a greater width than the first, allowing for uniform cooling and reduced installation area requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the pair of winding portions are arranged in a vertical arrangement to reduce installation area, then the installation area is reduced, but the distance between the side surface of the upper winding portion and the inner wall surface of the case increases, resulting in poor heat dissipation and higher losses
Solution Approach 1:
The patent applies asymmetry by making the second winding portion have a greater width than the first winding portion. This asymmetric design compensates for the increased distance from the case wall, ensuring that the second winding portion (which would otherwise have poor heat dissipation) maintains adequate thermal contact with the case through its extended width, thereby resolving the heat dissipation issue while keeping the vertical arrangement for compact installation area
Solution Approach 2:
The patent applies local quality by providing different widths for the first and second winding portions. The second winding portion, located farther from the case wall, is given a greater width to locally enhance its heat dissipation capability. This localized adjustment ensures that each winding portion has appropriate thermal management based on its specific position and heat dissipation needs
2Area of stationary object
If the case depth is increased to accommodate the vertical arrangement of winding portions, then the installation area is reduced, but the distance between the winding portions and the case wall increases, reducing heat dissipation efficiency
Solution Approach 1:
The asymmetric width design of the second winding portion compensates for the increased distance from the case wall caused by the deeper case. The greater width provides an extended surface area that maintains effective thermal coupling with the case, ensuring that the temperature of the second winding portion remains controlled despite the increased case depth required for vertical arrangement
3Ease of manufacture
If the second winding portion has the same width as the first winding portion, then the manufacturing is simplified, but the heat dissipation from the second winding portion is insufficient due to the increased distance from the case wall
Solution Approach 1:
The patent applies local quality by providing different widths for the first and second winding portions based on their specific heat dissipation requirements. The second winding portion, being farther from the case wall, is given a greater width to locally enhance its heat dissipation capability, while the first winding portion maintains its original width, optimizing overall thermal performance
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 achieves uniform cooling of both winding portions, reducing reactor losses and installation space requirements while minimizing the need for high thermal conductivity resins, thus lowering costs and enhancing heat dissipation.
Implementation Method 1
heat is less likely to be dissipated from the upper winding portion via the inner wall surface of the case
Data Source
AI summary
A reactor includes an assembly of a coil and a magnetic core; a case; and a sealing resin portion filling the case and sealing at least a portion of the assembly. The case has an inner bottom surface, and a pair of coil facing surfaces that face side surfaces of the coil. The pair of coil facing surfaces have inclined surfaces that incline away from each other in a direction from the inner bottom surface side to an opposite side to the inner bottom surface. The coil includes a first winding portion disposed on the inner bottom surface side, and a second winding portion disposed opposite of the inner bottom surface with respect to the first winding portion. The first winding portion and the second winding portion are in a vertical arrangement and are parallel with each other. The second winding portion is wider than the first winding portion.