Reactor Inner Interposed Member Design for Heat Dissipation
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Solution Overview
Problem
Conventional reactors face challenges in improving heat dissipation properties and magnetic characteristics, particularly due to limitations in the configuration of inner interposed members, which affect the distance between the winding and magnetic core portions, leading to restricted heat dissipation and magnetic path cross-sectional area.
Innovation Solution
The reactor design incorporates an inner interposed member with a thin portion and a thick portion, where the thin portion has a recessed inner peripheral face and the thick portion has a larger thickness, allowing for reduced clearances between the inner core and interposed member, and between the interposed member and winding portion, enhancing heat dissipation and magnetic path area without increasing the reactor size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the inner interposed member has a uniform thickness, then the insulation is simple to manufacture, but the heat dissipation distance is increased and magnetic path area is reduced
Solution Approach 1:
The inner interposed member employs varying thickness locally: a first thickness in the axial direction at the inner peripheral face region (where heat dissipation is critical) and a second thickness greater than the first thickness at other regions. This local variation reduces the heat dissipation distance between the magnetic core and winding while maintaining insulation performance, directly resolving the contradiction between heat dissipation efficiency and structural simplicity.
2Temperature
If the clearance between inner core and interposed member is increased, then the assembly is easier to manufacture, but the heat dissipation distance is increased
Solution Approach 1:
The design specifies that the inner peripheral face of the inner interposed member has a first thickness in the axial direction, creating a locally optimized region that reduces the clearance distance between the magnetic core and interposed member. This localized thickness reduction minimizes the heat dissipation distance while the overall structure maintains manufacturability, balancing heat dissipation requirements with manufacturing precision.
3Volume of moving object
If the reactor size is reduced, then the compactness is improved, but the magnetic path cross-sectional area is reduced
Solution Approach 1:
The invention optimizes the axial dimension by varying the thickness of the inner interposed member along the axial direction. By reducing the thickness at specific axial positions (where it contacts the magnetic core), the design increases the magnetic path cross-sectional area without increasing the overall reactor volume, effectively resolving the contradiction between compactness and magnetic performance through dimensional optimization.
Data Source
AI summary
A reactor includes a coil, a magnetic core having an inner core portion inside a winding portion, and an inner interposed member insulating the winding portion from the inner core portion. The inner interposed member includes a thin portion with a small thickness formed by a recess, and a thick portion with a thickness larger than that of the thin portion. The inner core portion includes a core-side projecting portion with a shape conforming to a shape of the inner peripheral face of the thin portion. The thickness of the thin portion is 0.2 mm or more and 1.0 mm or less, and the thickness of the thick portion is 1.1 mm or more and 2.5 mm or less. Clearances are in part of a portion between the inner core portion and the inner interposed member and of a portion between the inner interposed member and the winding portion.