Reactor Heat Dissipation via Finned Outer Core
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Solution Overview
Problem
The existing reactor designs for vehicle-mounted DC-DC converters face challenges in effectively dissipating heat generated due to high current flow, leading to internal temperatures exceeding 100°C, as the outer core covering obstructs heat dissipation.
Innovation Solution
A reactor design featuring a case with a heat-radiation structure at its inner wall surface, allowing the coil and inner core to be closer to the heat-dissipating surface, and an outer core formed from a mixture of magnetic material and resin for improved heat transfer, even when covered by a core member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer core portion covers the coil and inner core portion, then the magnetic circuit is closed and magnetic performance is improved, but heat dissipation is obstructed causing internal temperature to rise
Solution Approach 1:
The outer core portion is segmented into multiple heat-radiation fins that extend outward, creating separate heat dissipation pathways while maintaining the closed magnetic circuit structure. This segmentation allows heat to be radiated from multiple surfaces simultaneously without compromising magnetic performance.
Solution Approach 2:
The heat-radiation structure extends the outer core portion in the radial dimension, transforming the conventional flat outer surface into a three-dimensional finned structure. This dimensional expansion increases the heat radiation surface area without affecting the magnetic circuit's closed-loop integrity.
2Reliability
If the coil is completely covered by the core member, then magnetic flux containment is improved, but heat radiation performance deteriorates
Solution Approach 1:
The outer core portion is designed with different local qualities: the inner surface maintains high magnetic permeability for flux containment, while the outer surface features heat-radiation fins with optimized geometry for thermal emission. This local differentiation allows simultaneous achievement of magnetic containment and heat radiation.
Solution Approach 2:
The heat-radiation fins act as an intermediary structure between the coil and the external environment. They provide a thermal conduction pathway from the coil to the external space while maintaining the magnetic circuit's closed structure, effectively mediating between magnetic flux containment and heat dissipation requirements.
3Use of energy by moving object
If a closed magnetic circuit structure is used, then magnetic efficiency is improved, but heat dissipation capability is reduced
Solution Approach 1:
The outer core portion is constructed as a composite structure combining magnetic material for flux containment and a heat-radiation fin structure for thermal management. This composite design integrates both magnetic efficiency and heat dissipation functions into a single component, resolving the contradiction between closed magnetic circuit and heat dissipation capability.
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
Enhanced heat-radiation performance of the coil and inner core, effectively dissipating heat to maintain lower internal temperatures, even under high current conditions.
Implementation Method 1
The case has a heat-radiation structure at an inner wall surface, the heat-radiation structure being provided for at least one of the coil and the inner core portion
Implementation Method 2
The outer core portion has a shape corresponding to the heat-radiation structure
Implementation Method 3
the amount of heat generated by the coil may increase, and hence the internal temperature of the reactor may rise to high temperatures of 100° C. or higher
Data Source
AI summary
Provided is a reactor including a coil, and a core having an inner core portion arranged inside the coil and an outer core portion covering the outside of the coil. The inner core portion of the reactor has a higher saturation magnetic flux density than that of the outer core portion. The outer core portion has a lower permeability than that of the inner core portion, and is made of a mixture of a magnetic material and a resin. The case has a heat-transfer portion at an inner wall surface, as a heat-radiation structure for at least one of the coil and the inner core portion. With the reactor, even if the outside of the coil is covered with a core member, heat generated in the reactor can be effectively dissipated.