Reactor With Variable Thickness Insulator For Heat Dissipation

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Solution Overview

Problem

Conventional reactors for electric-powered vehicles face challenges in heat dissipation and magnetic characteristics, with limited size reduction and increased cross-sectional area of the magnetic path, due to thick inwardly interposed members and large distances between the wound and inner core portions.

Innovation Solution

A reactor design featuring a thin and thick portion configuration in the inwardly interposed member, with a thin portion of 0.2 mm to 1.0 mm and a thick portion of 1.1 mm to 2.5 mm, allowing intimate contact between the inner core, inwardly interposed member, and wound portions, enhancing heat dissipation and magnetic path area without increasing the reactor size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick inwardly interposed member is used to ensure insulation, then insulation reliability is improved, but the distance between the wound portion and inner core portion increases, worsening heat dissipation and magnetic characteristics

Engineering Contradiction:

Improveinsulation reliabilityVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The inwardly interposed member features variable thickness with thin portions (0.2-1.0 mm) at locations requiring insulation and thick portions (1.1-2.5 mm) at locations requiring enhanced insulation, allowing local optimization of both insulation reliability and heat dissipation performance

Inventive Principle:

Principle #3Local quality

2Reliability

If a thick inwardly interposed member is used to ensure insulation, then insulation reliability is improved, but the cross-sectional area of the magnetic path is reduced, worsening magnetic characteristics

Engineering Contradiction:

Improveinsulation reliabilityVSAvoidmagnetic path area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The inwardly interposed member has thin portions (0.2-1.0 mm) positioned to minimize interference with the magnetic path while maintaining necessary insulation, thereby preserving the cross-sectional area of the magnetic path and improving magnetic characteristics

Inventive Principle:

Principle #3Local quality

3Temperature

If the inwardly interposed member thickness is reduced to improve heat dissipation, then heat dissipation is improved, but insulation reliability deteriorates

Engineering Contradiction:

Improveheat dissipationVSAvoidinsulation reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The inwardly interposed member strategically places thin portions (0.2-1.0 mm) in regions where insulation requirements are lower but heat dissipation is critical, while maintaining thick portions (1.1-2.5 mm) in regions requiring higher insulation, achieving both improved heat dissipation and maintained insulation reliability

Inventive Principle:

Principle #3Local quality

4Volume of moving object

If the reactor size is reduced, then miniaturization is achieved, but the magnetic path area is reduced, worsening magnetic characteristics

Engineering Contradiction:

Improvereactor sizeVSAvoidmagnetic path area

Core Design Contradiction:

Volume of moving objectVSArea of stationary object

Solution Approach 1:

The variable thickness configuration of the inwardly interposed member with thin portions (0.2-1.0 mm) allows maximization of the magnetic path area within a compact reactor volume, enabling miniaturization while preserving magnetic characteristics

Inventive Principle:

Principle #3Local quality

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 improves heat dissipation and magnetic characteristics by reducing the distance between the inner core and wound portions, increasing the magnetic path area, and suppressing expansion and magnetostrictive vibrations, while maintaining productivity and dimensional accuracy.

Implementation Method 1

the inner core portion and the inwardly interposed member are in substantially intimate contact with each other, and the inwardly interposed member and the wound portion are in substantially intimate contact with each other

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

A magnetic core with an inner core portion is arranged inside the wound portion

Methodology Applied

Scientific EffectMagnetic flux: Magnetic Field

Data Source

PatentUS11282626B2Reactor

Publication Date: 2022.03.22 AUTONETWORKS TECH LTD

AI summary

A reactor includes a coil; a magnetic core with an inner core portion arranged inside the coil; and an inwardly interposed member insulating the coil from the inner core portion. The inwardly interposed member has a thin portion defined by a recess of an inner-circumferential surface, and a thick portion that is thicker than the thin portion. The inner core portion has, on an outer circumferential surface facing the inwardly interposed member, a core-side projection portion has a shape conforming to the inner-circumferential surface shape of the thin portion. The thin portion has a thickness of 0.2 mm to 1.0 mm inclusive, and the thick portion has a thickness of 1.1 mm to 2.5 mm inclusive. The inner core portion and the inwardly interposed member are in intimate contact with each other, and the inwardly interposed member and the wound portion are in intimate contact with each other.