Reactor Case with Multi-Level Bottom for Resin Stability
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Solution Overview
Problem
Conventional reactors for on-vehicle power converters face challenges with high power density, leading to increased temperature rise, insulation degradation, and manufacturing inefficiencies due to unstable mold resin charging and increased viscosity, resulting in reduced service life and higher costs.
Innovation Solution
A reactor design with a case having multiple inner bottom surfaces of varying heights to ensure stable positioning and insulation of the induction component, allowing for improved mold resin spreading and heat radiation, even with high viscosity fillers, thereby reducing resin charging variations and manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If higher power density is designed to reduce size and weight, then space utilization is improved, but temperature rise increases and insulation properties deteriorate
Solution Approach 1:
A mold resin is introduced as an intermediary substance between the coil and the case to provide thermal management and electrical insulation. The mold resin absorbs and dissipates heat while maintaining electrical isolation, enabling the reactor to achieve high power density without compromising insulation or overheating
Solution Approach 2:
The reactor employs a composite structure combining the coil, core, and mold resin. The mold resin acts as a composite material that simultaneously provides thermal conduction pathways for heat dissipation and electrical insulation properties, resolving the contradiction between compact size and temperature management
2Temperature
If alumina and aluminum hydroxide are mixed in mold resin to improve heat conduction and insulation, then heat radiation is improved, but viscosity increases and mold resin charging becomes unstable
Solution Approach 1:
The viscosity of the mold resin is controlled by adjusting parameters such as temperature and resin composition. By optimizing these parameters, the mold resin maintains appropriate flow characteristics for stable charging while still incorporating alumina and aluminum hydroxide fillers for improved heat conduction and insulation
Solution Approach 2:
The mold resin is designed with non-uniform filler distribution or varying resin composition in different regions to achieve optimal heat radiation in critical areas while maintaining manufacturability in other regions. This local optimization allows high filler content for heat conduction without excessive viscosity throughout the entire resin system
3Power
If core and coil are located in high density in the case, then power density is improved, but mold resin charging stability deteriorates and insulation becomes unreliable
Solution Approach 1:
The coil and core are pre-positioned and fixed in the case before mold resin charging. This preliminary positioning ensures that the high-density arrangement is maintained while providing a stable framework for subsequent mold resin injection, preventing charging instability and ensuring reliable insulation coverage
4Manufacturing precision
If multiple surfaces of different heights are provided in the case to improve mold resin spreading, then insulation stability is improved, but device complexity increases
Solution Approach 1:
The case is segmented into multiple regions with different surface heights, creating distinct zones for mold resin placement. This segmentation provides stable positioning for the coil and core while ensuring uniform mold resin spreading and reliable insulation coverage, with the added benefit that the segmented structure can be manufactured using standard molding techniques
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 solution enables efficient heat radiation, stable insulation, and extended service life while reducing manufacturing costs and time, suitable for high-power density applications like electric vehicles.
Implementation Method 1
heat is transferred to a sealing mold resin formed with respect to a case housing a reactor, and the heat is further radiated to the outside via a radiator plate
Implementation Method 2
alumina (Al2O3), aluminum hydroxide (AlOH3) and the like having insulation properties and a thermal conductivity higher than that of the resin of base material is mixed in a mold resin to be injected in the case
Data Source
AI summary
The invention provides a reactor to be built in a power converter. In the reactor, an induction component composed of a coil being a winding of a conductor wire, a core in which interior a magnetic path is formed and an insulation bobbin positioning and engaging a wire wound part of the coil is housed in a case to be soaked with a mold resin. Inner bottom face of the case has a plurality of surfaces having not less than two different heights letting the outside bottom of the case a reference surface, and the lower end face of the core is in contact with any of the case inner bottom surfaces excluding the lowest inner bottom surface. As a result, the reactor is suitable for on-vehicle applications to achieve reduced article variation as well as a longer service life, a shorter operation time and decreased cost.