Submerged Ferrite Transformer Cooling for High-Power Compact Designs
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Solution Overview
Problem
Conventional fluid-cooled transformers face challenges in achieving high power output while maintaining a reduced form factor and weight, as higher permeability materials generate more heat, requiring efficient cooling solutions that often add weight or are susceptible to induction heating.
Innovation Solution
A submerged ferrite transformer design with a fluid-cooled primary winding and magnetic core, where cooling fluid directly contacts the magnetic core and windings within a sealed enclosure, enhancing heat transfer and reducing weight through efficient cooling circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher permeability magnetic materials are used to increase power output by volume, then the transformer becomes more compact and delivers more power, but heat generation increases significantly requiring special cooling design
Solution Approach 1:
The patent uses fluid cooling circuits with pumps and flow distribution to actively remove heat from the magnetic core and windings. Cooling fluid is circulated through channels in the magnetic core and windings, using hydraulic principles to efficiently transport heat away from high-permeability materials that generate excessive heat during operation.
Solution Approach 2:
The patent introduces cooling fluid as an intermediary substance between the heat-generating magnetic components and the heat dissipation system. The fluid acts as a thermal mediator, absorbing heat from the magnetic core and windings and transporting it to external heat exchangers, enabling the use of high-permeability materials without thermal damage.
2Temperature
If mechanical heat sinks are placed in contact with magnetic material for cooling, then heat removal is achieved, but the structure becomes problematic due to induction heating from primary winding currents
Solution Approach 1:
The patent uses cooling fluid as an intermediary thermal transfer medium instead of direct mechanical contact between heat sinks and magnetic materials. This fluid intermediary eliminates the induction heating problem that occurs when conductive heat sinks are exposed to alternating magnetic fields from primary windings, while still achieving efficient heat removal through the fluid's thermal properties.
3Temperature
If transformer is filled with oil for magnetic structure cooling, then cooling effectiveness improves, but significant weight is added to the device
Solution Approach 1:
The patent changes the physical parameters of the cooling system by using controlled fluid circulation with specific flow rates, temperatures, and pressures rather than relying on large volumes of heavy oil. The system achieves equivalent or superior cooling effectiveness through optimized fluid dynamics parameters while significantly reducing the overall weight compared to oil-filled designs.
4Temperature
If conventional cooling structures are used with water cooled copper, then heat transfer is achieved, but the transformer volume increases and complicates handling
Solution Approach 1:
The patent integrates cooling channels directly within the magnetic core structure and windings, nesting the cooling system inside the transformer components rather than adding external cooling structures. This nested arrangement achieves effective heat transfer while minimizing the overall transformer volume and maintaining a compact form factor that facilitates handling.
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 design increases power performance, extends operational duty cycles, and reduces thermal stresses by efficiently cooling the transformer components, allowing for the use of higher permeability materials without significant weight increase.
Implementation Method 1
cooling fluid flows into the sealed enclosure to directly contact the magnetic core and the primary winding effectively submerging the magnetic core, the primary winding, and the secondary winding in flowing cooling fluid
Implementation Method 2
cooling fluid directly contacts the magnetic core and windings within a sealed enclosure, enhancing heat transfer
Implementation Method 3
a transformer assembly formed from a fluid-cooled primary winding wound about a magnetic core... After cooling the induction coil, the cooling fluid returns through a return line of the secondary winding
Data Source
AI summary
A transformer assembly is formed from a primary winding wound about a toroidal or other annularly shaped magnetic core. A secondary winding passes through a center of the magnetic core and about an exterior of the magnetic core. The transformer assembly is disposed within a sealed enclosure into which fluid is introduced to directly contact the magnetic core before exiting through an outlet, submerging the magnetic core, the primary winding, and the secondary winding in flowing fluid. The primary winding may be disposed within a flexible tubing through which fluid flows, or alternatively, the primary winding may be cooled via contact with the cooling fluid flowing through the sealed enclosure. The secondary winding may be either internally cooled via cooling fluid flowing therethrough, or externally cooled via the cooling fluid flowing through the sealed enclosure. In some embodiments, a separate coil cooling circuit is defined external to the sealed enclosure.