Hybrid Vehicle Reactor With Insulating Heat Dissipation Layer
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Solution Overview
Problem
Conventional reactors for hybrid vehicles face challenges in reducing size and weight while maintaining excellent heat dissipation characteristics, as aluminum cases require insulation, which hinders size reduction and expose the coil and magnetic core to environmental hazards when the case is eliminated.
Innovation Solution
A reactor design featuring a dividable case with a heat dissipation layer on the inner bottom face, using an insulating material with high thermal conductivity, and a pressing mechanism to ensure even contact between the coil and the heat dissipation layer, allowing for efficient heat transfer and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional aluminum case is used to store the coil and magnetic core, then the reactor possesses mechanical strength and protection from environmental hazards, but the reactor size and weight cannot be further reduced due to the need for electrical insulation between the conductive case and the coil
Solution Approach 1:
The invention extracts the electrical insulation function from the structural case by eliminating the conventional aluminum case entirely. The coil and magnetic core are stored directly in the resin molded product housing, which inherently provides both mechanical protection and electrical insulation without requiring additional insulating layers or increasing the reactor size
Solution Approach 2:
The resin molded product housing serves multiple functions simultaneously: it provides mechanical strength to protect the internal components, electrical insulation to prevent current leakage, and structural support to maintain the reactor's shape. This multi-functionality eliminates the need for separate case and insulation components
2Volume of moving object
If the case is eliminated to reduce size, then the reactor volume decreases, but the coil and magnetic core are exposed to environmental hazards such as dust and corrosion without mechanical protection
Solution Approach 1:
The invention uses a composite structure where the resin molded product housing combines protective and insulating properties. The housing is filled with resin material that provides both mechanical protection against environmental hazards and electrical insulation, creating a unified protective environment for the coil and magnetic core without increasing overall size
3Temperature
If sealing resin containing ceramic filler is used to enhance heat dissipation, then the heat dissipating characteristic improves, but the resin becomes brittle and prone to damage by thermal shock
Solution Approach 1:
The invention changes the thermal conductivity parameter of the resin molded product housing by selectively positioning high-thermal-conductivity resin in the heat dissipation region (bottom face) while using standard resin in other regions. This parameter optimization achieves excellent heat dissipation without adding brittle ceramic fillers throughout the entire housing, maintaining structural integrity and resistance to thermal shock
4Reliability
If a relatively great interval is provided between the coil and the inner face of the case to secure electrical insulating distance, then the electrical insulation is ensured, but the reactor size reduction becomes difficult
Solution Approach 1:
The invention extracts the electrical insulation function from the case structure and integrates it directly into the resin molded product housing. The housing itself is made of insulating material, eliminating the need for additional insulation layers and allowing the coil to be positioned closer to the housing inner face, thereby reducing the overall reactor size while maintaining adequate electrical insulating distance
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 a compact size with enhanced heat dissipation and insulation, protecting the coil and magnetic core from environmental hazards while maintaining efficient heat transfer to a cooling base.
Implementation Method 1
a heat dissipation layer formed on an inner face of the bottom plate portion to be interposed between the bottom plate portion and the coil... the heat dissipation layer is structured by an insulating material whose thermal conductivity is higher than 2 W/m·K
Implementation Method 2
the heat dissipation layer is structured by an insulating material whose thermal conductivity is higher than 2 W/m·K... the insulating characteristic of the insulating material refers to the voltage withstanding characteristic with which the coil and the bottom plate portion can electrically be insulated from each other
Data Source
AI summary
A reactor 1 of the present invention includes: a combined product 10 provided with a coil 2 and a magnetic core 3 where the coil 2 is disposed; and a case 4 storing the combined product 10. The case 4 includes: a bottom plate portion 40 fixed to a fixation target when the reactor 1 is installed in the fixation target; a side wall portion 41 attached to the bottom plate portion 40 to surround the combined product 10; and a heat dissipation layer 42 formed on the inner face of the bottom plate portion 40 to be interposed between the bottom plate portion 40 and the coil 2. The bottom plate portion 40 is made of aluminum, and the side wall portion 41 is made of an insulating resin. The heat dissipation layer 42 is made of an adhesive agent whose thermal conductivity is high and which exhibits an excellent insulating characteristic. Since the bottom plate portion 40 is structured as a separate member from the side wall portion 41, the heat dissipation layer 42 can easily be formed and, moreover, the heat dissipation layer 42 can be made of a material possessing an excellent heat dissipating characteristic. Since the insulator 5 evenly presses the coil 2 against the heat dissipation layer 42, an even more excellent heat dissipating characteristic is achieved.