Metallic Spacers for Induction Core Cooling
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Solution Overview
Problem
Existing electrical induction device cores with spacers for cooling channels occupy additional space, reduce fullness factor, and have low thermal conductivity, limiting their ability to handle thermal loads effectively, especially with new insulating fluids.
Innovation Solution
Using at least partially metallic spacers that provide higher thermal conductivity by increasing the surface area for heat transmission and convection, allowing for more efficient cooling and a more compact core design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If spacers are used to form cooling channels between metal sheets, then cooling capability is improved, but fullness factor is reduced and thermal conductivity is limited
Solution Approach 1:
The patent changes the material parameter of the spacers from non-metallic to metallic material, which fundamentally alters the thermal conductivity parameter. This allows the spacers to actively participate in heat transfer rather than merely providing mechanical spacing, thereby improving cooling capability while maintaining core compactness.
Solution Approach 2:
The invention uses composite construction by combining metallic spacer material with the insulating fluid in the cooling channels. The metallic spacers provide thermal conduction pathways while the insulating fluid provides convection cooling, creating a composite heat transfer system that overcomes the limitations of single-material approaches.
2Temperature
If spacers are used to form cooling channels, then cooling function is provided, but thermal conductivity is reduced due to low conductivity of spacer material
Solution Approach 1:
The patent fundamentally changes the thermal conductivity parameter by selecting metallic materials for spacers instead of traditional non-metallic materials. This parameter change transforms the spacers from thermal barriers to thermal conduits, enabling effective heat transfer from the metal sheets through the spacers to the cooling fluid.
Solution Approach 2:
The metallic spacers act as intermediary heat transfer elements between the core metal sheets and the insulating cooling fluid. They provide a thermally conductive pathway that bridges the gap between the heat-generating core and the cooling medium, enhancing the overall heat transfer efficiency.
3Temperature
If spacers cover substantial proportion of metal sheet surface, then cooling channels are formed, but surface area for thermal convection is reduced
Solution Approach 1:
The invention changes the functional parameter of the spacer surfaces from purely mechanical contact to active thermal exchange surfaces. By using metallic materials with high thermal conductivity, the spacer surfaces that contact the metal sheets become effective heat transfer interfaces, converting previously wasted coverage area into useful thermal conduction area.
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 metallic spacers enhance thermal conductivity and convection, enabling the core to withstand higher thermal loads, reduce production costs, and maintain effective cooling with fewer or smaller cooling channels, thus improving the core's efficiency and compactness.
Implementation Method 1
the spacers are at least partially comprised of metal. By the use of at least partially metallic spacers, greater thermal conductivity in the core is provided
Implementation Method 2
the outer surfaces of the spacers which are not in contact with the core metal sheets constitute convection surfaces for the evacuation of the heat to the cooling fluid
Data Source
AI summary
A core for an electric induction device includes a multiplicity of magnetizable metal sheets which form a stack of metal sheets resting on each other. Spacers that are each disposed between two metal sheets form at least one cooling channel which can be subjected to a greater thermal load and at the same time allows improved cooling. Said spacers are made, at least in part, of metal.