Copper Conductor with Ridges and Ventilation Holes for Heat Dissipation
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Solution Overview
Problem
Medium voltage switchgear copper conductors face limitations in performance and cost due to inefficiencies in heat management and current distribution, particularly with the skin and proximity effects, and existing designs do not adequately address these issues.
Innovation Solution
The copper conductor design incorporates cooling means such as ridges and ventilation holes to enhance convective and radiative cooling, optimizing copper placement for high current density areas and reducing overall copper usage, while maintaining the required cross-sectional area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional flat profile copper conductors are used, then the conductor structure is simple and manufacturing is easy, but the skin effect and proximity effect cause increased temperature rise and reduced conductivity efficiency
Solution Approach 1:
The conductor cross-section is segmented into multiple regions with different copper thicknesses. The thickness varies from the center toward the edges, creating distinct zones that optimize current distribution and reduce skin effect while maintaining structural integrity
Solution Approach 2:
Different regions of the conductor cross-section have different copper thicknesses tailored to local current density requirements. Areas experiencing higher current density have optimized copper content, while other areas have reduced thickness, creating non-uniform local properties that enhance overall performance
2Power
If copper conductor cross-sectional area is increased to handle high currents, then current carrying capacity improves, but the amount of copper increases leading to higher cost and weight
Solution Approach 1:
The conductor uses non-uniform copper thickness distribution where thicker sections are placed in regions experiencing higher current density and thinner sections where current density is lower. This local optimization allows the conductor to handle high currents efficiently while minimizing total copper consumption
Solution Approach 2:
The copper thickness parameter is varied continuously or in steps across the conductor cross-section. By changing the thickness parameter according to the current density distribution, the conductor achieves optimal current carrying capacity with reduced material usage
3Temperature
If conventional cooling methods are used, then the cooling system is simple, but heat dissipation efficiency is insufficient leading to higher operating temperatures
Solution Approach 1:
The cooling system utilizes the depth dimension by incorporating cooling channels within the conductor body itself. This internal cooling approach adds a new dimensional aspect to heat dissipation, allowing efficient heat removal without increasing the external footprint or adding complex external cooling apparatus
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 design improves conductivity and reduces temperatures, leading to cost savings by minimizing copper usage and enhancing cooling efficiency in medium voltage switchgear and ring core transformers.
Implementation Method 1
the at least one body comprises cooling means, wherein the cooling means comprises a plurality of ridges
Implementation Method 2
even improved radiative cooling
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a copper conductor (10). The copper conductor has at least one body (20) extending in a longitudinal axis. The at least one body comprises connection means (30) at a first position of the longitudinal axis and comprises connection means (40) at a second position of the longitudinal axis. Along at least a part of the longitudinal axis between the first position and the second position of the at least one body, the at least one body comprises cooling means (50).