Reactor Heat Dissipation via Interposed Sheet
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Solution Overview
Problem
Conventional reactors for hybrid automobiles face challenges in heat dissipation due to long heat transfer paths and low thermal conductivity materials, leading to increased temperatures and potential operational unreliability.
Innovation Solution
A reactor design featuring a heat dissipating sheet interposed between the coil and the inner core section, made of a wound coil wire and a magnetic core with a closed magnetic path, enhances heat transfer and dissipation by directly contacting the coil and inner core, while also restricting coil movement to prevent noise and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inner core section is covered with resin or bobbins are arranged on its outer circumference, then insulation between the coil and inner core section is enhanced, but the heat transfer path from the inner core section to outer core sections becomes long, making heat dissipation difficult
Solution Approach 1:
A heat dissipating sheet is introduced as an intermediary component between the inner core section and the coil. This sheet serves dual functions: it maintains insulation between the coil and inner core section while providing a thermal conduction path for heat dissipation from the inner core section to the coil and subsequently to the heatsink.
Solution Approach 2:
The heat dissipating sheet is made of a composite material that combines electrical insulation properties with high thermal conductivity. This allows the material to simultaneously provide electrical isolation and efficient heat transfer, resolving the contradiction between insulation and heat dissipation.
2Reliability
If gap plates made of resin are used between core pieces, then insulation is provided, but thermal conductivity is low, preventing effective heat transfer from core pieces to outer core sections
Solution Approach 1:
The heat dissipating sheet uses composite materials with both insulating and thermally conductive properties, enabling simultaneous achievement of electrical insulation and thermal conduction functions that were previously mutually exclusive.
Solution Approach 2:
The thermal conductivity parameter of the insulating material is significantly improved by using composite materials, transforming it from a thermal insulator (resin) to a thermal conductor while maintaining electrical insulation properties.
3Reliability
If conventional heat dissipation methods are used without direct contact between coil and inner core section, then insulation is maintained, but heat dissipation performance is insufficient leading to operational unreliability
Solution Approach 1:
The heat dissipating sheet acts as a mediator that enables direct thermal contact between the coil and inner core section while maintaining electrical insulation, thus improving heat dissipation without compromising insulation.
Solution Approach 2:
The functions of electrical insulation and thermal conduction are merged into a single component (the heat dissipating sheet), eliminating the need for separate insulating structures that would impede heat transfer.
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 improves heat dissipation performance by shortening heat transfer paths and preventing coil movement, thus enhancing reliability and reducing noise and damage risks.
Implementation Method 1
a heat dissipating sheet that is interposed at least partially between an inner circumferential surface of the coil and an outer circumferential surface of the inner core section... the heat dissipating sheet is in contact with the coil and the inner core section
Data Source
AI summary
A reactor that includes a coil made of a wound coil wire; a magnetic core on which the coil is arranged, and that forms a closed magnetic path, wherein the magnetic core has an inner core section that is arranged on an inside of the coil; and a heat dissipating sheet that is interposed at least partially between an inner circumferential surface of the coil and an outer circumferential surface of the inner core section that is opposite to the inner circumferential surface of the coil, wherein the heat dissipating sheet is in contact with the coil and the inner core section.