Rectangular Tubular Reactor Core for Inductance and Heat Dissipation
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Solution Overview
Problem
Conventional reactors face challenges in adjusting inductance and heat dissipation without increasing size, and the cooling pipe arrangement leads to a larger reactor size.
Innovation Solution
A reactor design with a magnetic core composed of two core portions made of different materials, allowing for independent adjustment of inductance and heat dissipation without a cooling pipe, and a rectangular tubular winding portion for enhanced heat dissipation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a magnetic core is made from a single material with low heat conductivity, then the inductance can be maintained, but the heat dissipation efficiency deteriorates
Solution Approach 1:
The magnetic core is divided into multiple core portions (first core portion and second core portion), each made from different materials with different heat conductivity. This segmentation allows heat to be dissipated through multiple pathways with different thermal properties, improving overall heat dissipation efficiency while maintaining the necessary magnetic properties for inductance.
Solution Approach 2:
Different core portions are assigned different material properties: some portions use materials with high heat conductivity for efficient heat dissipation, while other portions use materials optimized for magnetic properties. This local differentiation of material quality allows simultaneous optimization of both thermal and magnetic performance in different regions of the core.
2Temperature
If the magnetic core is made from composite materials with different heat conductivity, then the heat dissipation can be improved, but the manufacturing complexity increases
Solution Approach 1:
The core is segmented into separate portions that can be manufactured independently using different materials. This allows each portion to be optimized and manufactured separately, then assembled together, reducing the overall manufacturing complexity compared to creating a single complex composite material structure.
Solution Approach 2:
The patent uses composite materials in specific core portions where thermal performance is critical. By strategically applying composite materials only where needed rather than throughout the entire core, the manufacturing complexity is managed while still achieving improved heat dissipation in the necessary regions.
3Temperature
If cooling pipes are added around the case, then the heat dissipation performance is enhanced, but the device size increases
Solution Approach 1:
The heat dissipation function is extracted from the external cooling system and integrated directly into the magnetic core structure itself. By incorporating thermally conductive materials and heat dissipation pathways within the core portions, the need for external cooling pipes is reduced or eliminated, maintaining high heat dissipation performance while minimizing device size.
Solution Approach 2:
The heat dissipation structure is nested within the magnetic core itself rather than being added as an external component. The core portions with different thermal properties are arranged concentrically or in nested configurations, allowing heat to be conducted through multiple layers of different materials, achieving enhanced heat dissipation without increasing the external dimensions of the reactor.
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 reactor achieves easy adjustment of inductance and heat dissipation without size increase, reducing eddy current loss and enhancing manufacturing efficiency.
Implementation Method 1
the first core portion and the second core portion are constituted by compacts made of different materials
Implementation Method 2
reducing temperature and eddy current loss
Data Source
AI summary
Provided is a reactor including a coil and a magnetic core. The coil includes a winding portion, the number of winding portions is one, the winding portion has a rectangular tubular shape, the magnetic core is an assembly obtained by combining a first core portion and a second core portion, and the first core portion and the second core portion are constituted by compacts made of different materials.