Segmented Core Coil Structure With Airflow Cooling Paths
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Solution Overview
Problem
Existing coil devices face challenges in effectively dissipating heat, particularly in transformer and inductor applications, where cooling mechanisms are inadequate, leading to reduced performance and efficiency.
Innovation Solution
A composite coil device design incorporating E-shaped cores, a bobbin structure, and a case with integrated cooling air passages, allowing for enhanced heat dissipation through the use of cooling air channels and spaces between core leg parts, along with a resin-filled case for improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling air is introduced via through holes in the core, then heat dissipation is enhanced, but the core structure becomes more complex and manufacturing difficulty increases
Solution Approach 1:
The core is divided into multiple leg parts (first outer leg parts and second outer leg parts) that are spaced apart to form cooling spaces, rather than using a solid continuous structure. This segmentation creates natural cooling channels without requiring through holes, resolving the contradiction between heat dissipation and structural complexity
Solution Approach 2:
Cooling air is introduced as an intermediary substance that flows through the spaces between the spaced-apart leg parts. This mediator carries heat away from the coil and core without requiring direct structural modifications like through holes, achieving heat dissipation while maintaining structural simplicity
2Temperature
If cooling air passages are integrated into the case, then thermal management is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The cooling air passages are merged with the case structure itself, rather than being separate components. The case is designed to accommodate and guide cooling air flow, integrating the cooling function into the existing housing without adding separate cooling channels or complex assemblies, thus improving thermal management while maintaining ease of manufacture
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 design achieves improved heat dissipation properties, enhancing the performance and efficiency of transformer and inductor functions by effectively managing thermal buildup within the coil device.
Implementation Method 1
introduces cooling air to the inside of the core via the through hole. By supplying the cooling air to the inside of the core via the through hole, the core and the coil can be cooled
Implementation Method 2
a first wound wire part arranged around an outer circumference of the bobbin; a second wound wire part arranged directly or indirectly around an outer circumference of the first wound wire part
Data Source
AI summary
A coil device including a bobbin, a first wound wire part arranged around an outer circumference, a second wound wire part arranged around an outer circumference of the first, a first and second core installed to the bobbin, a case at least accommodating the bobbin, and a resin provided therein. The first core includes a first base part and a pair of first outer leg parts projecting therefrom, which are positioned opposite to each other in a first direction perpendicular to an axis direction of the bobbin. The second core includes a second base part and a pair of second outer leg parts projecting therefrom, which are positioned opposite to each other in the first direction. The pairs of outer leg parts are spaced apart so as to form a space therebetween along the second direction perpendicular to the axis direction and the first direction.