Reactor Heat Radiation Structure for Power Converter Thermal Management
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Solution Overview
Problem
The existing reactor designs for power converters, such as those in hybrid electric vehicles, face challenges in effectively dissipating heat generated due to copper and iron losses, leading to high internal temperatures, especially when the outer coil is covered with a core member.
Innovation Solution
A reactor design that incorporates a heat-radiation structure at the inner wall surface of the case housing the coil and core, allowing for improved heat dissipation by reducing the distance between the coil and core and the case, and utilizing a mixture of magnetic materials and resin for the outer core to facilitate efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the outer core portion covers the coil completely, then the magnetic circuit is improved, but heat dissipation deteriorates
Solution Approach 1:
The outer core portion is segmented into multiple sections along the axial direction, with air gaps introduced between segments. This segmentation maintains the magnetic circuit functionality while creating heat dissipation pathways, allowing heat to escape from the gaps without compromising the overall magnetic circuit integrity.
Solution Approach 2:
The outer core portion transitions from complete coverage to selective coverage, with local air gaps created at specific positions. This local modification allows heat dissipation at critical locations while maintaining magnetic circuit performance in other areas, applying the principle of making different parts have different functions.
2Temperature
If the case inner wall surface is modified with heat-radiation structure, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The heat-radiation structure uses protrusions with curved surfaces that correspond to the cylindrical outer shape of the coil. This curvature design maintains aesthetic appearance while effectively increasing the heat radiation surface area, and can be manufactured using standard molding techniques.
Solution Approach 2:
The heat-radiation structure adds dimensional complexity to the case inner wall by creating protrusions that extend toward the coil. This three-dimensional structure increases the heat exchange surface area without requiring separate heat dissipation components, integrating the function into the existing case structure.
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 heat-radiation performance of the reactor, effectively managing high temperatures and maintaining the internal temperature low, even when the outer coil is covered, thereby ensuring efficient operation of power converters.
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 heat-radiation structure may have a heat-transfer portion provided such that part of the inner wall surface of the case protrudes
Implementation Method 3
at least the outer core portion of the core is formed of a mixture of a magnetic material and a resin
Data Source
AI summary
A converter including a reactor as one of a component for the converter, the reactor comprising: a coil; a core having an inner core portion arranged inside the coil and an outer core portion covering the outside of the coil; and a case housing the coil and the core, wherein 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, wherein the heat-radiation structure is non-similar to an outer wall surface of the case, and is formed of the inner wall surface that is formed to correspond to an external shape of the at least one of the coil and the inner core portion.