Rake-Shaped Transformer Assembly for High-Density Cooling
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Solution Overview
Problem
Conventional transformer assemblies in power supplies have low power density and are prone to temperature increases due to a high volume of magnetic components and limited cooling surfaces, leading to hot-spot temperatures.
Innovation Solution
A transformer assembly with a rake-shaped core member design, featuring interconnected winding legs and return legs, allows for the integration of multiple transformers and chokes into single-phase configurations, enhancing power density and cooling efficiency by arranging windings in series and using distributed air gaps to manage magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple transformers and chokes are integrated into single-phase configurations using series-connected windings, then power density is enhanced and component volume is reduced, but the complexity of winding connections and magnetic flux management increases
Solution Approach 1:
The patent combines multiple transformers and chokes into a single integrated magnetic assembly with a unified core structure. Multiple windings are connected in series on shared magnetic paths, merging what would traditionally be separate components into one compact unit, thereby reducing total component volume while managing complexity through systematic connection patterns
Solution Approach 2:
The magnetic core assembly serves multiple functions simultaneously - it provides magnetic paths for multiple transformers and chokes, supports series-connected windings for voltage transformation, and incorporates distributed air gaps for flux management. This multi-functionality reduces the need for separate components and enhances power density
2Temperature
If conventional transformer assemblies with multiple separate cores are used, then magnetic flux management is simpler, but cooling surfaces are limited and hot-spot temperatures increase
Solution Approach 1:
By merging multiple transformers and chokes into a single integrated assembly with shared core structures, the patent creates extensive internal and external surface areas that can serve as cooling surfaces. The compact arrangement allows for more efficient heat dissipation compared to separate components, reducing hot-spot temperatures
Solution Approach 2:
The patent transitions from distributed separate components to a concentrated three-dimensional integrated assembly. This dimensional reorganization creates new surface areas for cooling while maintaining magnetic functionality, effectively increasing the cooling surface area relative to the overall device footprint
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 achieves high power density and efficient cooling, reducing the volume of magnetic components and minimizing temperature issues, thereby improving the performance of electric conversion devices.
Implementation Method 1
The primary winding and the secondary winding of a transformer are not connected to one another electrically. Furthermore, preferably, a choke may comprise one or more choke windings between which no energy is transferred via magnetic flux.
Implementation Method 2
The at least three winding legs and the at least two return legs are connected magnetically to the body portion.
Data Source
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AI summary
The present invention concerns a transformer assembly (1), especially for an electric conversion device (100), comprising at least one rake-shaped core member (2) respectively including a body portion (3), at least three winding legs (4), around each of which at least one electrical winding is wound, and at least two return legs (5), the at least three winding legs (4) and the at least two return legs (5) being connected magnetically to the body portion (3); wherein at least one electrical winding of at least one winding leg of at least one rake-shaped core member (2) is electrically connected in series with at least one electrical winding of at least one other winding leg (4) of said rake-shaped core member (2). The present invention also concerns an electric conversion device (100) comprising at least one transformer assembly (1).