Segmented Coil Core Structure for Direct Housing Heat Dissipation
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Solution Overview
Problem
Conventional coil devices require filling the housing with a sealing material to transfer heat generated in the coil body to the housing, which is inefficient and may lead to component detachment due to vibration in vehicles.
Innovation Solution
A coil device design where a core is formed by combining multiple core portions, with one core portion having a longitudinal direction along the winding axis and another stacked on the attachment surface of the housing, allowing direct heat dissipation from the conductive wire turns to the housing without the need for a sealing material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If sealing material is used to transfer heat from coil body to housing, then heat transfer is achieved, but device complexity increases and reliability decreases due to potential component detachment
Solution Approach 1:
The core is divided into multiple core portions with different orientations. The first core portion has its longitudinal direction along the winding axis, while the second core portion is stacked on the first core portion. This segmentation allows heat to be transferred from different parts of the coil body to the housing through different pathways, eliminating the need for sealing material filling.
Solution Approach 2:
The patent introduces a new spatial dimension for heat transfer by stacking core portions in the vertical direction (along the winding axis) rather than only horizontally. The combined surfaces of the core portions are parallel to the winding axis, creating a three-dimensional heat dissipation structure that directly contacts the housing at multiple levels, thereby achieving heat transfer without requiring sealing material to fill the housing space.
2Temperature
If sealing material is used to transfer heat, then heat dissipation is enabled, but reliability worsens due to component detachment risk under vibration
Solution Approach 1:
The patent merges the structural support function with the heat transfer function. The core portions are directly mounted on the housing attachment surface, combining mechanical support and thermal conduction into a single integrated structure. This eliminates the need for separate sealing materials that could detach under vibration, as the core itself provides both structural stability and heat dissipation pathways.
Solution Approach 2:
The core structure serves dual purposes: it provides mechanical support for the coil windings and simultaneously acts as a heat dissipation pathway to the housing. The first core portion and second core portion work together to conduct heat from the coil body directly to the housing, making the core self-sufficient for both support and thermal management functions without requiring additional sealing materials.
3Temperature
If sealing material fills the housing, then heat transfer path is established, but manufacturing complexity increases
Solution Approach 1:
The core is segmented into multiple portions that can be manufactured separately and then assembled on the housing. This segmentation simplifies manufacturing by allowing each core portion to be produced independently using standard machining processes, then mounted directly to the housing without requiring complex housing filling operations with sealing materials.
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 design enables efficient heat transfer from the coil body to the housing without using a sealing material, reducing component complexity and the risk of detachment due to vibration, while maintaining effective heat dissipation.
Implementation Method 1
the heat generated in the coil body is dissipated to the housing from each turn of the conductive wire
Data Source
AI summary
A coil device includes a core portion whose longitudinal direction is along a winding axis of a conductive wire and a core portion other than the core portion. In a core, the core portion is provided on an attachment surface of a housing 3, the core portion is stacked on the core portion, and the combined surfaces where the core portions are combined with each other are parallel to the winding axis.