Reactor Pressing Frame Segmentation for Thermal Contact
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Solution Overview
Problem
The existing reactor designs face challenges in attaching the reactor main body to a cooler due to a large reactive force generated by the flexible heat dissipation sheet, which requires a significant reduction in the distance between the resin cover and the cooler, making the attachment process difficult.
Innovation Solution
The design incorporates a pressing frame that extends along the outer periphery of the coil's bottom surface, allowing it to be displaced vertically and coupled only to the central section of the resin cover, reducing the contact area and the fixing force required, thereby facilitating the attachment process while maintaining tight adhesion of the coil to the heat dissipation sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat dissipation sheet is pressed tightly against the coil and resin cover to achieve good thermal contact, then thermal resistance is reduced, but the reactive force increases making attachment difficult
Solution Approach 1:
The pressing frame is divided into a fixed central section (coupled to the resin cover) and a movable peripheral section. This segmentation allows the peripheral section to yield to the reactive force from the heat dissipation sheet while the central section maintains pressing force, resolving the contradiction between achieving good thermal contact and making attachment easy.
Solution Approach 2:
The pressing frame transitions from a completely rigid structure to a dynamic structure where the peripheral section can move vertically relative to the resin cover. This dynamic characteristic allows the system to adapt to the reactive force during attachment while maintaining effective thermal contact pressure where needed.
2Reliability
If the pressing frame is rigidly coupled to the resin cover to maintain pressing force, then thermal contact is improved, but the fixing force required increases
Solution Approach 1:
The pressing frame is segmented into a fixed central portion coupled to the resin cover and a movable peripheral portion. This segmentation concentrates the coupling force at the central section while allowing the peripheral section to move, reducing the total fixing force required while maintaining effective thermal contact at the coil contact points.
Solution Approach 2:
The pressing frame exhibits different mechanical properties at different locations: the central section is rigid and coupled to maintain pressing force, while the peripheral section is movable to reduce fixing force requirements. This local differentiation resolves the contradiction between maintaining thermal contact quality and reducing overall fixing force.
3Stability of the object's composition
If the pressing frame contacts the resin cover over a large area, then stability is improved, but the fixing force and attachment difficulty increase
Solution Approach 1:
The pressing frame is segmented into a small central coupled section and a larger movable peripheral section. The central section provides stable coupling with the resin cover over a small area, while the peripheral section's ability to move reduces the fixing force required, resolving the contradiction between stability and attachment ease.
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 configuration reduces the fixing force needed for attachment, suppresses thermal resistance, and makes the process easier by limiting the abutment surface and allowing elastic deformation of the pressing frame, ensuring a secure and efficient cooling mechanism.
Implementation Method 1
a first bottom surface as a bottom surface of the first coil and a second bottom surface as a bottom surface of the second coil are aligned in a same plane. The first bottom surface and the second bottom surface are configured to be pressed against an upper surface of the cooler via the heat dissipation sheet
Implementation Method 2
The pressing frame is configured to press the heat dissipation sheet toward the cooler
Implementation Method 3
The heat dissipation sheet is flexible. Thus, a reactive force is generated from the heat dissipation sheet to the coil and the resin cover by pressing the coil and the resin cover against the heat dissipation sheet
Data Source
AI summary
A reactor includes a heat dissipation sheet and a main body. The main body includes a first coil, a second coil, a resin cover and a pressing frame. The resin cover has a central section that covers side surfaces of the first and second coil between the first and second coil. The pressing frame extends along outer peripheries of bottom surfaces of the first coil and the second coil. The pressing frame is configured to press the heat dissipation sheet toward the cooler. The pressing frame has a coupled section that is coupled to a lower surface of the central section. The pressing frame is able to be displaced in a vertical direction with respect to the resin cover other than the central section.