Integrated Polymer Winding Support for Compact Power Transformers
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Solution Overview
Problem
Conventional support structures for inductive devices like power transformers, made from cellulose-based materials, are complex, costly, and have suboptimal mechanical and electrical properties, leading to over-design and increased thickness due to anisotropic properties and high dielectric permittivity.
Innovation Solution
A single, integrated support structure formed from polymer materials using additive manufacturing, combining a press structure for force distribution, an insulator structure for electrical insulation, and a coolant flow structure with orifices, which reduces material usage and complexity while enhancing mechanical and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cellulose-based materials (laminated wood or press board) are used for support structures, then electrical insulation is provided, but the structure requires increased thickness due to high dielectric permittivity and anisotropic properties
Solution Approach 1:
The patent changes the material parameter from cellulose-based materials to polymer materials, which have lower dielectric permittivity and isotropic properties. This parameter change allows the support structure to maintain electrical insulation functionality while reducing the required thickness, directly resolving the contradiction between reliability and length.
2Ease of manufacture
If multi-part support structures are used combining several parts manufactured individually, then assembly flexibility is provided, but manufacturing complexity and joining requirements (gluing) increase
Solution Approach 1:
The patent merges multiple separate support structure parts into a single integrated polymer component. This combining eliminates the need for multiple manufacturing steps, assembly operations, and joining processes (such as gluing), thereby reducing device complexity while maintaining ease of manufacture through single-step production.
3Reliability
If conventional cellulose-based materials are used, then support structure is provided, but mechanical strength and resilience are reduced especially at elevated temperatures
Solution Approach 1:
The patent changes the material parameters by selecting polymer materials with superior mechanical properties, including higher strength and resilience. These materials maintain their mechanical stability at elevated temperatures better than cellulose-based materials, directly resolving the contradiction between reliability and strength.
4Reliability
If conventional support structures are used, then basic support function is provided, but chemical resistance against coolant substances at elevated temperature is insufficient
Solution Approach 1:
The patent changes the material composition from cellulose-based materials to chemically resistant polymer materials. This parameter change provides superior resistance against degradation from coolant substances at elevated temperatures, resolving the contradiction between reliability and chemical resistance to harmful factors.
5Productivity
If integrated single-part support structure is used, then manufacturing speed and robustness are improved, but design flexibility for multi-functional integration may be limited
Solution Approach 1:
The patent applies multi-functionality by designing a single polymer support structure that simultaneously provides mechanical support, electrical insulation, and integrated coolant flow channels. This universal design allows the structure to perform multiple functions without requiring separate components, maintaining design flexibility while achieving fast single-step manufacturing.
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 solution results in a more robust, compact, and cost-effective support structure with improved mechanical and electrical properties, reduced material usage, and efficient coolant flow, enabling the design of compact power transformers with lower no-load losses.
Implementation Method 1
an insulator structure configured to electrically insulate the holding structure from the at least one winding
Implementation Method 2
a coolant flow structure configured to guide and distribute a flow of a liquid coolant to or from different parts of the at least one winding
Implementation Method 3
a press structure configured to transfer and distribute a compression force from a holding structure to the at least one winding
Data Source
AI summary
The present disclosure relates to a support structure for at least one winding of an inductive device, in particular a power transformer, comprising a press structure configured to transfer and distribute an compression force from a holding structure to the at least one winding, an insulator structure configured to electrically insulate the holding structure from the at least one winding, and a coolant flow structure configured to guide and distribute a flow of a liquid coolant to or from different parts of the at least one winding. The press structure, the insulator structure and the coolant flow structure are formed as one integrated part comprising a polymer material. The integrated part comprises a plurality of orifices for passage of the liquid coolant from a first side facing the holding structure to a second side facing the at least one winding.