Planar Transformer Cooling via Interlayer Heat Shunts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical power transformers face challenges in effectively dissipating heat generated during use, with existing cooling methods often being inefficient or expensive, particularly for coil-shaped conductors.
Innovation Solution
The design incorporates a core with a conductor pack featuring alternating layers of conducting and insulating materials, and a cooling member, such as a heat pipe or heat shunt, strategically placed between conductor packs to facilitate heat dissipation through convection and condensation processes, allowing for efficient cooling without external pumps or devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used for coil-shaped conductors, then cooling capability is provided, but system complexity and cost increase
Solution Approach 1:
The planar conductor packs are designed to be naturally cooled by ambient air flowing across their surfaces, eliminating the need for external pumps, fans, or complex cooling systems. The flat geometry enables effective passive convection cooling.
Solution Approach 2:
The patent replaces active mechanical cooling systems with passive thermal convection based on the inherent geometry of planar conductor packs, substituting complex mechanical cooling infrastructure with simple ambient air flow.
2Temperature
If conventional cooling methods are used, then cooling capability is provided, but cost increases
Solution Approach 1:
The transformer design allows self-cooling through ambient air convection, eliminating expensive cooling equipment and reducing both capital and operational costs while maintaining effective heat dissipation.
Solution Approach 2:
The patent employs simple, inexpensive planar conductor packs with inherent cooling surfaces rather than expensive, complex cooling systems, achieving cost-effective heat management through geometric design.
3Adaptability or versatility
If coil-shaped conductors are used, then traditional transformer design is maintained, but heat dissipation efficiency decreases
Solution Approach 1:
The patent transitions from three-dimensional coil-shaped conductors to two-dimensional planar conductor packs, increasing the surface area-to-volume ratio and enabling more efficient heat dissipation to the surrounding ambient air.
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 heat dissipation efficiency, reducing the operational temperature of the transformer and potentially lowering costs by eliminating the need for expensive cooling systems, while maintaining reliable electrical performance.
Implementation Method 1
facilitate heat dissipation through convection and condensation processes
Implementation Method 2
facilitate heat dissipation through convection and condensation processes
Data Source
AI summary
The present disclosure includes an electrical power transformer that may include a core and a conductor pack. A conductor pack may include a conducting layer disposed around a portion of the core, a first planar insulating layer disposed on a first side of the conducting layer, and a second planar insulating layer disposed on a second side of the conducting layer. A cooling member may be disposed adjacent to the conductor pack. A method of manufacturing an electrical power transformer may include providing a core and providing a plurality of planar conductor packs. The planar conductor packs including a plurality of planar conducting layers and a plurality of planar insulating layers. The method may include inserting a cooling member between insulating layers of adjacent ones of the plurality of planar conductor packs.