Transformer Coldplate With Raised Feature and Bracket

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Solution Overview

Problem

Standard coldplates in electric and hybrid-electric vehicles are insufficient for dissipating the heat generated by transformers, leading to inefficiencies in the auxiliary power module's operation.

Innovation Solution

A coldplate design featuring a recessed main portion with a raised feature for contacting the transformer's winding and a bracket member for securing and dissipating heat from the transformer's surfaces, utilizing thermal interface material for enhanced heat conduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a standard coldplate is used for heat dissipation, then the structure is simple and easy to manufacture, but the heat dissipation capability is insufficient for transformer operation

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidcoldplate structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The coldplate is divided into a main portion and a separate bracket member, each serving specific heat dissipation functions. The main portion contacts the transformer core while the bracket member contacts the winding, allowing targeted heat dissipation from different heat-generating components without requiring a completely redesigned monolithic structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention adds a vertical dimension to heat dissipation by incorporating a raised feature on the main portion that contacts the winding from above, while the bracket member provides additional contact points on the transformer core. This multi-level contact approach increases heat dissipation surface area without significantly increasing the overall footprint of the coldplate assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Temperature

If additional heat dissipation features are added to the coldplate, then the heat dissipation capability is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidcoldplate manufacturing ease

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

By separating the coldplate into a main portion and a bracket member, the invention allows each component to be manufactured using simpler processes. The bracket member can be designed as a separate L-shaped or U-shaped component that is easier to fabricate and attach, rather than integrating complex three-dimensional heat dissipation features into a single monolithic coldplate structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bracket member acts as an intermediary component that bridges the main portion of the coldplate and the transformer assembly. This intermediate element provides the additional heat dissipation contact surfaces while maintaining manufacturing simplicity, as it can be attached using standard fastening methods rather than requiring complex integrated manufacturing processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The design provides additional heat dissipation capabilities beyond standard coldplates, ensuring efficient operation of the auxiliary power module by effectively transferring heat from the transformer's surfaces and winding to the coldplate.

Implementation Method 1

The floor of the recess is configured for contacting the bottom surface of the transformer for dissipating heat generated by the transformer. The raised feature is configured for contacting the winding of the transformer for dissipating heat generated by the transformer.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

utilizing thermal interface material for enhanced heat conduction

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8902582B2Coldplate for use with a transformer in an electric vehicle (EV) or a hybrid-electric vehicle (HEV)

Publication Date: 2014.12.02 LEAR CORP

AI summary

A coldplate for use with a transformer in an electric vehicle (EV) or a hybrid-electric vehicle (HEV). The coldplate includes a main portion having a recess formed therein, the recess having a floor configured for contacting a bottom surface of a transformer for dissipating heat generated by the transformer. The main portion includes a raised feature configured for contacting a winding of the transformer for dissipating heat generated by the transformer. The coldplate also includes a bracket member for use in securing the transformer in the recess of the main portion, the bracket member configured for contacting the main portion and the transformer for dissipating heat generated by the transformer. The bracket member includes a contact surface for contacting a top surface of the transformer, the contact surface having an area sufficient to contact substantially all of the top surface of the transformer.