Split Metal Plate Choke Coil for Electric Compressor Heat Dissipation
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Solution Overview
Problem
Electric compressors used in vehicles face challenges with heat dissipation due to the poor thermal performance of annular electrical conductors in common mode choke coils, which are essential for noise reduction in inverter devices.
Innovation Solution
The design includes a common mode choke coil with an annular core and winding wires, where the annular electrical conductor is split into two metal plates with different resistance values, with the first metal plate thermally coupled to the housing and the second plate electrically connected to the circuit board, enhancing heat dissipation by concentrating heat in areas with higher resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an annular electrical conductor covers the winding wires in a common mode choke coil, then common mode noise is reduced, but heat dissipation performance deteriorates
Solution Approach 1:
The annular electrical conductor is divided into first and second metal plates with different electrical resistance values. The first metal plate has higher resistance and is positioned to receive more heat from the winding wires, while the second metal plate has lower resistance. This segmentation allows different parts of the conductor to handle heat differently, improving overall heat dissipation while maintaining noise reduction functionality.
Solution Approach 2:
Different regions of the electrical conductor are given different electrical resistance values to create localized heat management. The first metal plate with higher resistance is strategically positioned to absorb and dissipate heat from the winding wires, while the second metal plate with lower resistance provides alternative current paths. This local quality differentiation enables effective heat dissipation without compromising the common mode noise reduction function.
2Object-affected harmful factors
If heat is generated in the annular conductor by leakage magnetic flux, then common mode noise is suppressed, but thermal stress increases
Solution Approach 1:
The electrical conductor is segmented into multiple metal plates with different resistance values, allowing heat generated by leakage magnetic flux to be distributed across different components. The first metal plate with higher resistance generates controlled heat for noise suppression, while the second metal plate with lower resistance provides a heat sink pathway, thereby reducing thermal stress on any single component.
Solution Approach 2:
The first metal plate with higher electrical resistance acts as an intermediary that converts magnetic flux energy to heat in a controlled manner for noise suppression, while the second metal plate with lower resistance serves as a heat dissipation pathway. This intermediary structure manages thermal stress by distributing the heat generation and dissipation across different components.
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 performance by actively dissipating heat generated in the choke coil, reducing thermal stress and enhancing the cooling efficiency of the electric compressor.
Implementation Method 1
The first metal plate is thermally coupled to the housing and disposed between the housing and the pair of winding wires
Implementation Method 2
heat is generated in the annular conductor, but the annular conductor has poor heat dissipation performance
Data Source
AI summary
An electric compressor includes a compression part, an electric motor, an inverter device, and a housing. The inverter device includes an inverter circuit, a noise reduction unit, and a circuit board. The noise reduction unit includes a common mode choke coil and a smoothing capacitor. The common mode choke coil includes an annular core, a pair of winding wires, and an annular electrical conductor. The electrical conductor is split into a first metal plate and a second metal plate in a circumferential direction. The first metal plate is thermally coupled to the housing. The second metal plate is electrically connected to the first metal plate. An electrical resistance value of the first metal plate is larger than that of the second metal plate.