New energy transformer with enhanced heat dissipation structure

Abstract

The invention discloses a new energy transformer with an enhanced heat dissipation structure, and relates to the technical field of power equipment.The new energy transformer comprises a fixing frame, at least one longitudinally-arranged coil assembly and at least one draught fan arranged at the bottom, and the coil assembly comprises a primary coil, a secondary coil, a supporting structure and a plurality of heat dissipation fins; the primary coil and the secondary coil are separated in the radial direction through the supporting structure, and an annular heat dissipation gap is formed. The heat dissipation fins are arranged and fixed on the supporting structure in the gap, an air outlet of the fan is aligned with a bottom opening of the heat dissipation gap, and the heat dissipation fins extend in the axial direction of the coil and are arranged at intervals in the circumferential direction; and a heat dissipation air channel for simultaneously supporting forced convection of the fan and natural rising of hot air is formed. According to the technical scheme provided by the invention, the built-in heat dissipation fins are combined with the directional air duct, so that the heat dissipation area and the airflow efficiency are remarkably increased, efficient, reliable and compact-structure heat dissipation is realized, and the heat dissipation device is particularly suitable for scenes with high power and high heat dissipation requirements, such as new energy automobile charging.

Description

Technical Field

[0001] This invention belongs to the field of power equipment technology, and specifically relates to a new energy transformer with an enhanced heat dissipation structure. Background Technology

[0002] During operation, transformer windings generate significant Joule heat due to resistance. If this heat cannot be dissipated promptly, it can lead to excessively high winding temperatures, accelerating the aging of insulation materials, affecting transformer efficiency, lifespan, and even causing malfunctions. This problem is particularly prominent in the charging of new energy vehicles, where power density is high and the operating environment is demanding.

[0003] Traditional transformer cooling methods primarily rely on natural convection of external air or additional radiators, resulting in long cooling paths and low efficiency. Some improvements involve installing ventilation channels between windings or using liquid cooling technology; however, the former often leads to uneven heat dissipation due to complex structures and obstructed airflow, while the latter is costly and carries the risk of leakage. Furthermore, the common concentric cylindrical winding structure, with its fixed and narrow gap between the inner and outer windings, is detrimental to airflow and heat exchange.

[0004] Therefore, how to provide a transformer internal heat dissipation solution that is simple in structure, cost-controllable, and significantly improves heat dissipation efficiency has become an urgent problem to be solved in this field.

[0005] To address the aforementioned issues, this application proposes a new energy transformer with an enhanced heat dissipation structure. Summary of the Invention

[0006] To address the problems mentioned in the background section, this invention provides a new energy transformer with an enhanced heat dissipation structure, exhibiting high-efficiency heat dissipation.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a new energy transformer with an enhanced heat dissipation structure, the core of which includes a fixing frame, at least one set of coils, and at least one fan. The coils are mounted longitudinally (vertically) on the fixing frame. The fan is located at the bottom of the transformer. The coils include a primary coil, a secondary coil, a supporting structure, and several heat dissipation fins. The primary coil and the secondary coil are radially separated from each other by the supporting structure, thereby forming an annular heat dissipation gap between them. The heat dissipation fins are disposed and fixed on the supporting structure within the heat dissipation gap to increase the heat exchange area. The air outlet of the fan is precisely aligned with the bottom opening of the heat dissipation gap to directly and efficiently guide the cooling airflow into the core heat-generating area.

[0008] As a further optimization of the technical solution of the present invention, the cross-sectional profile of the primary coil is designed to be elliptical, and the cross-sectional profile of the secondary coil is circular, with the secondary coil sleeved outside the primary coil. This combination of ellipse and circle optimizes the mechanical structure and space utilization, providing a basis for forming an effective heat dissipation channel.

[0009] Furthermore, the support structure specifically includes an inner support member for winding and fixing the primary coil, and an outer support member for winding and fixing the secondary coil. The heat dissipation fins serve as connectors, with both ends connected between the inner and outer support members, thereby achieving a dual function of mechanical connection and heat conduction.

[0010] Regarding the arrangement of the heat dissipation fins, they preferably extend along the axial direction (i.e., the vertical direction) of the primary coil and are evenly spaced along the circumferential direction of the coil group. This arrangement maximizes the contact area with the flowing air and has a minimal impact on airflow resistance.

[0011] The heat dissipation gap is constructed as a continuous vertical ventilation gap that completely extends vertically around the coil axis. When the transformer is installed as a whole, ensure that its coil axis is arranged vertically. At this time, the vertical ventilation gap naturally forms one or more three-dimensional heat dissipation channels.

[0012] This three-dimensional heat dissipation duct is designed to support two heat dissipation mechanisms working in tandem: one is forced convection cooling provided by the bottom fan; the other is passive convection through the "chimney effect," where the air is heated by the windings themselves and rises naturally. These two mechanisms can be combined to significantly improve heat dissipation efficiency.

[0013] As a typical application embodiment of the present invention, the transformer is a three-phase transformer, comprising three sets of coil groups arranged equidistantly along the fixed frame to meet the requirements of a three-phase power system.

[0014] Correspondingly, the number of fans is preferably two sets, arranged symmetrically front and back with respect to the axis of the fixed frame. These two sets of fans work together to deliver cooling airflow evenly and effectively to the heat dissipation gaps of the three coil sets.

[0015] The magnetic circuit portion of the transformer includes an iron core. The iron core extends longitudinally through the middle of the primary coil (or, for an elliptical coil, through its geometric center), and both ends of the iron core are securely fixed to the mounting bracket. Multiple iron cores and the robust mounting bracket together form a stable "fence structure," providing a high-strength mounting support foundation for all coil assemblies.

[0016] In addition, to facilitate external electrical connections, terminal blocks are also fixedly installed on the mounting bracket. These terminal blocks are arranged one-to-one with the coil groups and are reliably connected to the wires inside the corresponding coils.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. Extremely high heat dissipation efficiency: The supporting structure actively creates a continuous and unobstructed vertical ventilation gap, precisely guiding the airflow from the bottom fan to the heat source (winding gap). Combined with the natural assistance of the chimney effect, a highly efficient "active forced air cooling + passive natural convection" composite heat dissipation system is formed, where heat is directly and quickly carried away.

[0018] 2. Compact structure and large heat exchange area: The large number of heat dissipation fins built into the ventilation gap greatly expand the heat exchange surface area between the winding and the cooling air, efficiently transferring the heat inside the winding to the airflow, solving the problem of insufficient heat dissipation area on the surface of traditional windings.

[0019] 3. Excellent mechanical stability: The support structure not only forms heat dissipation gaps and mounts fins, but also stabilizes the relative positions of the inner and outer coils. The "fence structure" formed by the iron core and the fixed frame has high overall mechanical strength, strong resistance to vibration and impact, and is suitable for harsh environments.

[0020] 4. Reliable and Intelligent Operation: This heat dissipation structure does not rely solely on a fan. Even in the event of fan failure or low-speed operation, the powerful "chimney effect" maintains considerable heat dissipation capacity, improving the overall reliability of the system. Furthermore, the fan speed can be adjusted according to temperature rise, achieving intelligent and energy-saving operation. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a schematic diagram of the front structure of the present invention; Figure 3 This is a top view of the structure of the present invention; Figure 4 This is a schematic diagram of the coil support component in this invention; Figure 5 This is a top view of the coil assembly in this invention. Figure 6 This is a three-dimensional structural diagram of the coil assembly in this invention; In the diagram: 1. Fixing frame; 2. Coil group; 3. Fan; 21. Primary coil; 22. Secondary coil; 23. Heat sink fins; 24. Iron core. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0023] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0024] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0025] Reference Figures 1 to 3 This embodiment provides a new energy transformer with an enhanced heat dissipation structure, which has an overall rectangular vertical structure. The transformer mainly includes a rectangular mounting frame 1 welded from metal profiles, which constitutes the mechanical body and mounting foundation of the equipment. Inside the mounting frame 1, three sets of identical coil groups 2 are installed longitudinally (vertically) at equal intervals along its length, forming a three-phase transformer. At the bottom of the mounting frame 1, two axial flow fans 3 are installed. These two fans 3 are symmetrically arranged one in front of the other, with the longitudinal center symmetry plane of the mounting frame 1 as the reference, and their air outlet direction is vertically upward.

[0026] Reference Figures 4 to 6 Taking one coil group 2 as an example, its internal structure will be explained in detail. The core of each coil group 2 is an iron core 24 made of stacked silicon steel sheets. This iron core 24 runs vertically through the center of the entire coil group.

[0027] Primary coil and support structure: Outside the core 24, an elliptical cylindrical inner support is fitted, made of a high-strength insulating material (such as reinforced PBT or epoxy glass cloth). The primary coil 21 (e.g., as a low-voltage winding) is tightly and uniformly wound on this elliptical inner support, so that its cross-sectional profile is elliptical (e.g., ...). Figure 5 (As shown).

[0028] Formation of the gap between the secondary coil and the heat dissipation: A cylindrical outer support, made of the same insulating material, is provided around the primary coil 21 and its inner support. The secondary coil 22 (e.g., as a high-voltage winding) is wound on this cylindrical outer support, which has a circular cross-sectional profile. These inner and outer supports together constitute the "support structure" described in this invention. Through precise design, the inner and outer supports maintain a constant radial distance, thereby forming a completely continuous annular heat dissipation gap between the elliptical cross-section of the primary coil 21 and the circular cross-section of the secondary coil 22.

[0029] Integration of heat dissipation fins: like Figure 4 and Figure 6 As shown, within the aforementioned annular heat dissipation gap, multiple metal heat dissipation fins 23 (preferably made of aluminum) extending along the coil axis (i.e., the vertical direction) are evenly distributed. These heat dissipation fins 23 are arranged at intervals along the circumference of the coil assembly. The inner edge of each heat dissipation fin 23 is firmly connected to the inner support (or directly to the skeleton of the primary coil 21), and the outer edge is firmly connected to the outer support. The connection method can be insert injection molding, thermally conductive adhesive bonding, or mechanical locking. The heat dissipation fins 23 thus simultaneously play three key roles: 1) mechanically connecting and reinforcing the inner and outer support; 2) serving as an efficient heat conduction path to expand the thermal surface area, rapidly dissipating the heat generated by the primary coil 21 and the secondary coil 22; 3) themselves constituting a turbulence element within the heat dissipation duct, enhancing heat transfer.

[0030] Overall mechanical fixation (fence structure): like Figure 1 and Figure 2 As shown, the upper and lower ends of the iron cores 24 of the three coil groups 2 are firmly locked to the upper and lower crossbeams of the fixing frame 1 by high-strength insulating pads and fastening bolts. The three straight iron cores 24 and the sturdy rectangular fixing frame 1 together form a rigid "fence" type main structure, which provides extremely high mechanical stability and can effectively withstand the weight of the coil groups, electromagnetic forces, and vibrations during equipment operation.

[0031] Airflow and heat dissipation path: like Figure 1 and Figure 2As shown, the air outlets of the two symmetrically arranged fans 3 at the bottom are directly opposite the inlet of the heat dissipation gap at the bottom of each coil group 2. This heat dissipation gap is a continuous vertical ventilation gap that runs through the coil axis in the vertical direction.

[0032] Forced air cooling mode: When the fan 3 is started, cooling air is forced to be blown upwards from the bottom into the vertical ventilation gap. As the air flows through the narrow channel filled with high-temperature heat dissipation fins 23, it undergoes intense forced convection heat transfer and is heated before being discharged at high speed from the top of the coil assembly.

[0033] Chimney effect mode: Even when the fan 3 is not running or is running at low speed, the air in the heat dissipation gap is heated by the windings and heat dissipation fins 23, reducing its density, and will automatically flow upward along the gap and be discharged from the top. The escape of hot air causes a negative pressure to form at the bottom, which automatically draws in cold air to replenish it, forming a continuous natural convection heat dissipation based on the "chimney effect".

[0034] like Figure 3 As shown, on the side of the mounting bracket 1, there are terminals corresponding to each phase coil group 2 (not shown in the figure, located at the lead wire position of the coil group 2). These terminals are reliably connected to the lead wires of the primary coil 21 and secondary coil 22 of the corresponding coil group 2 through internal busbars or cables, facilitating the access of external power lines.

[0035] In summary, the transformer in this embodiment creates a highly efficient three-dimensional composite heat dissipation system through its unique "elliptical inner ring + circular outer ring" winding layout, heat dissipation fins 23 built into the winding gaps, and bottom-aligned air supply fan 3. Combined with its robust grid-like mechanical structure, it is particularly suitable for applications such as new energy vehicle charging, which have high heat dissipation requirements, complex operating environments, and stringent reliability requirements.

[0036] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A new energy transformer with an enhanced heat dissipation structure, characterized in that: Including the mounting bracket (1); At least one set of longitudinally arranged coil groups (2) are mounted on the fixing frame (1); At least one fan (3) is installed at the bottom of the transformer; The coil group (2) includes a primary coil (21), a secondary coil (22), a support structure, and several heat dissipation fins (23). The primary coil (21) and the secondary coil (22) are radially separated by the support structure to form a heat dissipation gap between them; The heat dissipation fins (23) are disposed within the heat dissipation gap and fixed to the support structure; The air outlet of the fan (3) corresponds to the bottom opening of the heat dissipation gap.

2. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: The primary coil (21) has an elliptical cross-sectional profile, the secondary coil (22) has a circular cross-sectional profile, and the secondary coil (22) is sleeved outside the primary coil (21).

3. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: The support structure includes an inner support for winding and fixing the primary coil (21), and an outer support for winding and fixing the secondary coil (22); the heat dissipation fins (23) are connected between the inner support and the outer support.

4. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: The heat dissipation fins (23) extend along the axial direction of the primary coil (21) and are spaced apart along the circumferential direction of the coil group (2).

5. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: The heat dissipation gap is a continuous vertical ventilation gap that runs around the coil axis and extends vertically.

6. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: When the transformer is installed as a whole, its coil axis is arranged in a vertical direction; the heat dissipation gap forms a three-dimensional heat dissipation air duct, which is configured to dissipate heat through the forced convection of the fan (3) and the chimney effect formed by the natural rise of hot air.

7. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: The transformer is a three-phase transformer, comprising three sets of coil groups (2) arranged equidistantly along the fixed frame (1).

8. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: The number of the fans (3) is two sets, and they are symmetrically arranged front and back with the axis of the fixed frame (1) as the reference, and together they send air to the heat dissipation gap of the three sets of coil groups (2).

9. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: The iron core (24) runs longitudinally through the middle of the primary coil (21), and its two ends are fixed to the fixing frame (1), so that the fixing frame (1) and the multiple iron cores (24) together constitute a fence structure for installing and fixing all the coil groups (2).

10. The new energy transformer with enhanced heat dissipation structure according to claim 1, characterized in that: A terminal block is fixed on the (1) and is correspondingly provided with the coil group (2) and connected to the wire in the corresponding coil.

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