Reactor Core With Embedded Cooling Pipe For Heat Dissipation
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Solution Overview
Problem
Conventional reactors with heat radiation structures face challenges in achieving efficient heat dissipation due to limited contact area between the reactor and the heat sink, leading to potential operational instability and damage from excessive temperature.
Innovation Solution
A reactor design featuring a core made of magnetic powder-containing resin that directly contacts the coil and accommodates a cooling member, ensuring a large contact area for efficient heat radiation, with the cooling member embedded within the core to radiate heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat sink plate is used to radiate heat from the outer surface of the reactor, then heat radiation from the outer surface is accelerated, but the contact area between the reactor and heat sink is insufficient, reducing radiation efficiency
Solution Approach 1:
The invention transitions from surface-level heat radiation (2D contact) to volumetric heat radiation (3D contact) by embedding the cooling member inside the coil. This dimensional change allows heat to be extracted from the interior volume of the reactor where heat is generated, rather than only from the outer surface, significantly increasing the effective contact area between the cooling member and the heat-generating components.
Solution Approach 2:
The cooling member is nested inside the coil structure, with the coil wound around the cooling member. This nested arrangement allows the cooling member to be positioned within the heat-generating region, maximizing thermal contact between the cooling member and the coil while maintaining the functional integrity of both components.
2Stability of the object's composition
If an iron core is used, then the reactor structure is stable, but it becomes difficult to arrange a cooling member inside the coil
Solution Approach 1:
The invention uses a composite core structure consisting of magnetic powder mixed with resin or plastic. This composite material provides the necessary magnetic properties for reactor operation while being easier to manufacture and modify than solid iron cores. The composite structure allows for integrated cooling channels or embedded cooling members without compromising structural integrity or magnetic performance.
Solution Approach 2:
The invention changes the material parameter from solid iron to magnetic powder-containing composite material. This parameter change transforms the core from a rigid, difficult-to-modify structure to a more flexible composite that can be easily formed with internal cooling passages or can accommodate embedded cooling members, thereby reducing the complexity of cooling system integration.
3Device complexity
If cooling is applied only to the outer surface, then the structure is simple, but heat generated inside the coil cannot be effectively removed
Solution Approach 1:
The invention moves heat removal from the external surface (2D) to the internal volume (3D) by placing the cooling member inside the coil. This allows direct heat extraction from the heat-generating region, dramatically improving heat removal efficiency without requiring complex external cooling structures.
Solution Approach 2:
The cooling member acts as an intermediary between the heat-generating coil and the external cooling system. By positioning the cooling member inside the coil, it serves as a thermal bridge that efficiently conducts heat from the coil to the coolant, improving the overall heat transfer pathway without adding external complexity.
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
This design enhances the operational stability of the reactor and surrounding electronic components by efficiently dissipating heat, reducing the risk of damage from excessive temperature and improving the overall heat radiation properties.
Implementation Method 1
a core made of magnetic powder-containing resin filled in the spaces inside and outside the coil so that the core comes in contact with the coil in a direct and tight manner
Implementation Method 2
a heat radiating member for radiating heat generated by a coil
Data Source
AI summary
A reactor is provided with a coil, a core, and a case. The coil generates magnetic flux in response to supply of current thereto. The core is made of magnetic powder-containing resin filled in spaces inside and outside of the core. The case accommodates therein the coil and the core. The reactor is also provided with a cooling pipe (cooling member), which is arranged to be in contact with the core. A power converter is provided with semiconductor modules, a cooler, and the reactor. In the power converter, the cooler is arranged partially being in contact with the core of the reactor.