Cast Resin Transformer Windings With Interleaved Heat-Conductive Plates
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Solution Overview
Problem
Cast resin transformers are limited in high and medium frequency applications due to heat generation and insulation requirements, leading to potential damage and failure, while conventional paper insulation restricts isolation levels in high power high frequency transformers.
Innovation Solution
A winding assembly with interleaved thermally conductive plates and coils encased in cast resin dielectric material, allowing efficient heat removal and maintaining dielectric isolation strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cast resin is used to maintain isolation requirement in high frequency transformers, then dielectric isolation strength is improved, but heat removal capability deteriorates due to thick resin layers blocking heat flow
Solution Approach 1:
The winding assembly is segmented into multiple discrete turns rather than continuous windings, allowing individual thermal management for each turn. Thermally conductive plates are placed between specific turns to create localized heat transfer paths without requiring thick cast resin layers, thus maintaining both isolation strength and heat removal capability.
Solution Approach 2:
Thermally conductive plates are introduced as intermediary elements between the windings and the cast resin. These plates facilitate heat transfer from the windings to the cast resin, allowing the cast resin to maintain its dielectric isolation function while the plates handle the thermal management, resolving the contradiction between isolation strength and heat removal.
2Temperature
If conventional paper insulation is used to maintain isolation requirements, then heat removal capability is improved, but dielectric isolation strength deteriorates with limited isolation levels
Solution Approach 1:
The invention uses a composite structure combining cast resin dielectric material with thermally conductive plates. The cast resin provides superior dielectric isolation strength while the thermally conductive plates provide heat removal pathways, achieving both high isolation levels and effective thermal management that neither material could achieve alone.
3Reliability
If thick layers of cast resin are used to maintain isolation requirement, then dielectric isolation strength is improved, but thermal conduction deteriorates due to heat flow barrier
Solution Approach 1:
Instead of uniformly thick cast resin layers throughout, the invention applies thermally conductive plates at specific locations between turns where heat generation is highest. This localized approach maintains dielectric isolation strength where needed while providing targeted thermal conduction pathways, avoiding the heat flow barrier problem of uniformly thick resin layers.
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
Enables the use of cast resin in high frequency transformers by effectively removing heat without degrading insulation, preventing overheating and device failure.
Implementation Method 1
The first set of thermally conductive plates is interleaved with the sets of turns of the first coil, with each plate disposed adjacent to one of the sets of turns of the first coil, to transfer heat away from the first coil
Implementation Method 2
The first coil, the second coil, and the first and second sets of thermally conductive plates are encased in the cast resin dielectric material, to electrically insulate first coil and the second coil
Data Source
AI summary
A winding assembly for a transformer device includes a first and second coil with a plurality of windings, and a first set and a second set of thermally conductive plates. The first and second coils include a plurality of interleaved sets of turns. The plates of the first and second sets of the thermally conductive plates are interleaved with the sets of turns of the first and second coils respectively, and are disposed adjacent to one of the sets of turns of the first and second coils respectively, to transfer heat away from the coils. The first and second coils and the first and second sets of thermally conductive plates are encased in the resin dielectric material.