Multi-Chamber Transformer Mounting Layout for Compact PCB Cooling
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Solution Overview
Problem
Existing multi-chamber transformers for solid-state lighting applications face challenges in compactness, heat dissipation, voltage overload capacity, and cost, particularly when mounted on PCBs, due to increased overall dimensions and difficulties in automated production and electrical connections.
Innovation Solution
A transformer design with a slim coil former and flexible stand-off, allowing windings to be arranged alongside each other, reducing overall dimensions, improving insulation, and facilitating cooling, while maintaining efficient electromagnetic interference reduction and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-chamber transformer design is used, then the device structure is simple, but the transformer cannot be selectively deactivated and may continue to operate after damage
Solution Approach 1:
The transformer is divided into multiple independent chambers (first chamber, second chamber, third chamber) that can be selectively deactivated. Each chamber contains separate windings and can be independently controlled through individual circuit breakers, allowing the transformer to maintain partial operation even when one chamber is damaged or requires maintenance.
2Adaptability or versatility
If multiple chambers are used, then selective deactivation is possible, but the mounting and wiring complexity increases
Solution Approach 1:
The mounting assembly provides a nested structure where multiple chambers are housed within a common transformer housing. The circuit breakers are integrated into the mounting assembly, creating a hierarchical organization that simplifies wiring and mounting while enabling independent control of each chamber.
Solution Approach 2:
The mounting assembly serves multiple functions simultaneously: it provides structural support for all chambers, integrates the circuit breakers, facilitates wiring connections, and enables selective deactivation. This multi-functional design reduces the number of separate components needed and simplifies the overall system.
3Area of stationary object
If chambers are closely spaced, then the transformer footprint is reduced, but heat dissipation becomes more difficult
Solution Approach 1:
The mounting assembly provides localized heat dissipation pathways for each chamber. Thermal management features are distributed throughout the structure, with each chamber having access to cooling channels or heat sinks positioned in immediate proximity, allowing efficient heat removal despite close spacing between chambers.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A multi-chamber transformer (10) comprises a plurality of windings (Lpri, Ls1, Ls2, Laux) wound on a coil former (100), which is provided with a plurality of transverse flanges (104, 106) that define mutually insulated winding chambers arranged alongside one another in a longitudinal direction (X100) of the coil former between two outermost transverse flanges (104). A transformer core (C) surrounds the plurality of windings (Lpri, Ls1, Ls2, Laux) wound on the coil former (100), with a first outer surface (C1) and a second outer surface (C2) that on opposite sides with respect to the windings (Lpri, Ls1, Ls2, Laux). The coil former (100) comprises lateral extensions at the opposite ends of the first outer surface (C1) of the core (C), which carry electrically conductive pins (200) having proximal ends coupled to the windings (Lpri, Ls1, Ls2, Laux) and distal ends projecting from the lateral extensions of the coil former (100). The first outer surface (C1) of the transformer core (C) is a surface lying in a plane (PC1), and the electrically conductive pins (200) project from the lateral extensions of the coil former (100) starting from a plane (P200) of the lateral extensions (108) that is set in (d) with respect to the plane (PC1) of the first outer surface (C1) of the transformer core (C).