Double-Choke Transformer Assembly With Integrated Heatsink Cooling
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Solution Overview
Problem
Managing cooling of power devices such as uninterruptible power supplies (UPSs) is challenging due to the need for increased power density, higher operating temperatures, and higher waste heat temperatures, with existing cooling solutions being inefficient and costly.
Innovation Solution
A multi-transformer assembly is thermally coupled to a heatsink using thermal conductors, where two transformers with specific winding configurations generate in-phase and out-of-phase magnetic fields to optimize cooling, while being compact and efficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional cooling solutions are used for power devices, then cooling function is provided, but cooling efficiency is insufficient and costs are high
Solution Approach 1:
The patent combines the magnetic shielding function and the heat dissipation function into a single component. The dual-choke structure uses the magnetic cores themselves as heat dissipation elements, eliminating the need for separate cooling systems. The first and second chokes are positioned on opposite sides of the heat sink, with their magnetic cores directly coupled to the heat sink surfaces, thereby integrating cooling into the transformer structure.
Solution Approach 2:
The magnetic cores of the transformers serve dual purposes: providing magnetic shielding and acting as heat dissipation elements. The cores are directly coupled to the heat sink, allowing them to self-dissipate heat without requiring additional active cooling components. The structure uses its own magnetic cores for both electromagnetic function and thermal management.
2Power
If power density is increased, then more power is processed, but heat generation increases requiring better cooling
Solution Approach 1:
The patent divides the heat dissipation function across multiple segments - the first heat dissipation surface and the second heat dissipation surface of the heat sink. Each choke is coupled to a separate surface, distributing the thermal load. This segmentation allows higher power density by providing multiple thermal pathways without concentrating heat in a single location.
3Temperature
If higher operating temperatures are allowed, then waste heat management is improved, but component reliability may decrease
Solution Approach 1:
The heat sink acts as an intermediary between the generating components (magnetic cores) and the environment. It provides a controlled thermal pathway that manages heat flow, allowing higher operating temperatures at the source while maintaining component reliability through efficient heat transfer to the heat sink surfaces.
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 enhances power density and allows for higher operating temperatures with improved waste heat management, reducing mechanical stress and costs by optimizing cooling efficiency and simplifying the design.
Implementation Method 1
The first primary winding and the first secondary winding may be configured to generate in-phase magnetic fields that cancel each other responsive to receiving at least one signal from at least one of the first input or the second input. The second primary winding and the second secondary winding may be configured to generate in-phase magnetic fields that cancel each other
Implementation Method 2
A heatsink may be positioned between the first core and the second core, with the heatsink including a first side and a second side, the first side preferably being thermally coupled to the first core and the first set of windings by a first thermal conductor and the second side preferably being thermally coupled to the second core and the second set of windings by a second thermal conductor
Data Source
Figure 1
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Figure 4~5
AI summary
A multi-transformer assembly includes a first transformer having a first core and a first set of windings, a second transformer having a second core and a second set of windings, and a heatsink positioned between the first core and the second core. The heatsink includes a first side and a second side. The first side of the heatsink is opposite the second side of the heatsink, and thermally coupled to the first core and the first set of windings. The first side is thermally coupled to the first core and the first set of windings by a first thermal conductor. The second side is thermally coupled to the second core and the second set of windings. The second side is thermally coupled to the second core and the second set of windings by a second thermal conductor.