Induction Core Segmentation for Transverse Cooling Channels
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Solution Overview
Problem
Existing electrical induction device cores with laminations are costly and complex to produce, and current cooling channel arrangements do not effectively utilize the high thermal conductivity of the metal sheets, leading to inefficient heat dissipation and limited design options.
Innovation Solution
The core is designed with laminations of varying widths, forming steps between stacks, and segmented partial laminated cores with gaps that create cooling channels transverse to the layer plane, utilizing the longitudinal thermal conductivity of the metal sheets for efficient cooling and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cooling channels are formed parallel to the layer plane by inserting strips or spacers, then cooling channels can be easily formed, but the favorable heat conduction parallel to the layering direction of the metal sheets cannot be utilized
Solution Approach 1:
Instead of forming cooling channels parallel to the layer plane as in conventional designs, the patent inverts the approach by creating cooling channels that extend perpendicular to the layer plane of the laminated sheets. This is achieved by segmenting the core into multiple partial laminated cores with gaps between them, allowing cooling channels to traverse through the thickness of the core rather than running parallel to the laminations.
Solution Approach 2:
The patent transitions from two-dimensional cooling channels (parallel to the layer plane) to three-dimensional cooling channels that extend through the thickness direction of the laminated core. This dimensional change allows the cooling channels to utilize the high thermal conductivity of the metal sheets in the longitudinal direction, improving heat dissipation efficiency.
2Loss of energy
If amorphous core materials are used to reduce no-load losses, then no-load losses are reduced, but material costs increase and processing becomes difficult
Solution Approach 1:
The patent changes the geometric parameters of the core by varying the width of laminations to create steps between stacks of laminations. This parameter change allows for the formation of cooling channels and segmented structures using conventional grain-oriented, cold-rolled sheet metal, thereby maintaining ease of manufacture while achieving improved cooling efficiency.
3Loss of energy
If the width of laminations is varied to form steps between stacks, then cooling channels can be formed and heat dissipation improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the core into multiple partial laminated cores by varying the width of laminations in different stacks. This segmentation creates gaps between the partial laminated cores that form cooling channels, enabling effective heat dissipation while maintaining a structured and organized core design.
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 reduces the space required for cooling, increases the fill factor, and allows for easier and more cost-effective production, while enabling effective heat dissipation and adaptable design options for both layered and wound cores.
Implementation Method 1
the heat originating from the no-load losses is dissipated to different degrees to the surface along and across the plane of the layer. This is expressed in a thermal conductivity that usually differs by a factor of 6...7.
Implementation Method 2
a gap extending perpendicularly to the layer plane is formed between the two partial laminated cores and the Gap forms a cooling channel or at least a section of a cooling channel
Data Source
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AI summary
The invention relates to a core (1) for an electric induction device with a plurality of laminated cores (2), each formed by laminated sheets (11, 11.1, 11.2), wherein the laminated cores (2) lie on top of each other parallel to the layer plane of the laminated sheets (11, 11.1, 11.2). According to the invention, at least one of the laminated cores (2) is segmented and has at least two partial laminated cores (3), the two partial laminated cores (3) each having their sheet end faces (3a) that are transverse, in particular perpendicular, to the layer plane of the laminated sheets (11, 11.1, 11.2).2) are positioned opposite each other, the sheet end faces (3a) of the two partial sheet stacks (3) have a distance to each other through which a gap extending perpendicular to the layer plane is formed between the two partial sheet stacks (3) and the gap forms a cooling channel (4) or at least a section of a cooling channel (4) whose longitudinal direction extends transversely, in particular perpendicularly, to the layer plane of the laminated sheets (11, 11.1, 11.2).