Thermally Conductive Bobbin for Transformer Core Cooling

Solution Overview

Problem

High-power medium frequency transformers face overheating issues due to high power density and thermal environments, leading to increased production costs and complexity in achieving required operating performance.

Innovation Solution

An electrical device with a thermally conductive dielectric bobbin that directly contacts the magnetic core, featuring ribs as contact elements to transfer heat to a cooling channel, allowing for efficient heat evacuation using a cooling medium, thereby optimizing thermal performance and reducing the need for external cooling means.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If high-powered fans and highly thermally conductive casting materials are used to prevent overheating, then thermal performance is improved, but production costs and device complexity increase

Engineering Contradiction:

Improvethermal performanceVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The bobbin is designed to integrate multiple functions: it provides mechanical support for the windings, serves as a thermal management system through direct contact with the magnetic core via rib-like contact elements, and acts as a structural component of the transformer. This merging of support, cooling, and structural functions into a single component eliminates the need for separate cooling fans and complex thermal management systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bobbin's own structure is utilized for thermal management. The rib-like contact elements are formed as integral parts of the bobbin, allowing it to conduct heat away from the magnetic core using its own material properties and geometry, without requiring external cooling devices or additional thermal management components.

Inventive Principle:

Principle #25Self-service

2Temperature

If high-powered fans and highly thermally conductive casting materials are used to prevent overheating, then thermal performance is improved, but production costs increase

Engineering Contradiction:

Improvethermal performanceVSAvoidproduction costs

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The bobbin is designed to integrate multiple functions: it provides mechanical support for the windings, serves as a thermal management system through direct contact with the magnetic core via rib-like contact elements, and acts as a structural component of the transformer. This merging of support, cooling, and structural functions into a single component eliminates the need for separate cooling fans and complex thermal management systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bobbin's own structure is utilized for thermal management. The rib-like contact elements are formed as integral parts of the bobbin, allowing it to conduct heat away from the magnetic core using its own material properties and geometry, without requiring external cooling devices or additional thermal management components.

Inventive Principle:

Principle #25Self-service

3Volume of moving object

If the transformer is mounted inside a relatively small compartment with high power density, then space utilization is improved, but thermal performance deteriorates

Engineering Contradiction:

Improvespace utilizationVSAvoidthermal performance

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The cooling approach transitions from external cooling (fans mounted outside the transformer) to internal cooling through the bobbin structure. The rib-like contact elements create thermal conduction paths within the transformer's internal structure, allowing heat to be conducted away through the bobbin's geometry rather than relying on external air flow, thus enabling effective cooling in compact spaces.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution enhances thermal performance, reduces operating temperature, increases reliability, and extends the device's lifetime, enabling smaller, denser designs with flexible adaptation to changing applications without additional cooling means.

Implementation Method 1

the bobbin is made of a thermally conductive dielectric material... the first contact element is configured as a conducting element that conducts or transfers away heat produced by the magnetic core

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20230402224A1Electrical Device

Publication Date: 2023.12.14 ABB (SCHWEIZ) AG

AI summary

An electrical device includes a magnetic core, a bobbin extending about and partially covering the magnetic core, wherein the bobbin is made of a thermally conductive dielectric material, wherein the bobbin further comprises an outer body connectable to an inner body, wherein the inner body comprises at least a first contact element being formed as a rib that is configured to directly contact a surface of the magnetic core.