Power Converter Windings with High Thermal Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power converters face challenges in efficiently dissipating heat generated by thin copper foil windings, which are prone to overheating due to their small conductor cross-sectional area, and are difficult to downsize while maintaining electrical insulation and heat dissipation.
Innovation Solution
A power converter design featuring windings bent to align with the magnetic core, with a first insulating member for electrical insulation and a second insulating member with higher thermal conductivity for efficient heat dissipation, positioned between the windings and metal sidewalls to enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If windings are formed as thin copper foil patterns to reduce size, then the power converter can be downsized, but heat dissipation becomes insufficient due to small conductor cross-sectional area
Solution Approach 1:
The windings are bent to have a portion extending in the direction in which the magnetic core extends, transitioning from a planar configuration to a three-dimensional arrangement. This dimensional change increases the surface area available for heat dissipation while maintaining the compact footprint of the power converter, effectively resolving the contradiction between downsizing and heat dissipation efficiency
Solution Approach 2:
A second insulating member with high thermal conductivity is introduced as an intermediary between the windings and the external environment. This mediator facilitates efficient heat transfer from the windings to the surroundings, enabling effective heat dissipation despite the use of thin copper foil windings with limited cross-sectional area
2Volume of moving object
If windings are bent to align with the magnetic core to reduce size, then the power converter can be downsized, but electrical insulation becomes more difficult to maintain
Solution Approach 1:
The insulating structure is divided into two distinct segments: a first insulating member positioned between the windings and the magnetic core, and a second insulating member with high thermal conductivity positioned between the windings and the external environment. This segmentation allows each insulating member to be optimized for its specific function, with the first member providing electrical insulation and the second member facilitating heat dissipation, thereby maintaining both electrical insulation and heat dissipation efficiency in the downsized configuration
Solution Approach 2:
The patent employs composite insulating structures combining materials with different properties. The first insulating member uses materials optimized for electrical insulation, while the second insulating member uses materials with high thermal conductivity. This composite approach allows the system to simultaneously achieve electrical insulation and efficient heat dissipation in the compact bent winding configuration
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 design achieves downsizing of the power converter, ensures electrical insulation between windings and magnetic cores, and facilitates high-efficiency heat dissipation from the windings, addressing the overheating issues of conventional designs.
Implementation Method 1
The second insulating member has a thermal conductivity higher than a thermal conductivity of the first insulating member
Data Source
AI summary
A power converter includes a magnetic core, a plurality of windings, a plurality of metal sidewalls, a first insulating member, and a second insulating member. The plurality of windings are each wound around the magnetic core and bent to have a portion extending in a direction in which the magnetic core extends. The plurality of metal sidewalls are disposed outside the plurality of windings and extend in the direction in which the magnetic core extends. The first insulating member is disposed between the plurality of windings and between the windings and the magnetic core. The second insulating member is disposed on an outside of the plurality of windings and in contact with each of the plurality of sidewalls and each of the plurality of windings. The second insulating member has a thermal conductivity higher than a thermal conductivity of the first insulating member.