Toroidal Transformer Cold Plate With Radial Heat Transfer Paths
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Solution Overview
Problem
Existing thermal management systems for toroidal transformers on cold plates are inefficient in dissipating heat due to thermal interface resistances and lack of optimized heat transfer pathways.
Innovation Solution
A cold plate with a machined cavity that integrates a toroidal transformer, featuring concentric fins and a conductive encapsulant to facilitate radial heat transfer, coupled with a coolant flow channel for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a toroidal transformer is placed on a cold plate, then the transformer can be cooled, but thermal interface resistances prevent efficient heat dissipation
Solution Approach 1:
A thermally conductive encapsulant material is introduced as an intermediary between the toroidal transformer and the cold plate cavity. This encapsulant fills the interface gap and provides a continuous thermal conduction path, eliminating air gaps and improving thermal contact. The encapsulant acts as a mediator that transfers heat more effectively from the transformer to the cold plate, resolving the thermal interface resistance problem.
Solution Approach 2:
Concentric fins are added to the cold plate cavity structure, creating additional radial heat transfer pathways. The fins extend in the radial direction, increasing the surface area for heat dissipation and providing multiple dimensional paths for heat to travel from the transformer to the coolant. This dimensional enhancement overcomes the limitations of simple planar contact.
2Temperature
If conventional cooling methods are used, then the system structure is simple, but heat transfer pathways are insufficient
Solution Approach 1:
The heat transfer process is segmented into multiple distinct pathways: radial heat transfer through the encapsulant, heat conduction through the cold plate cavity walls, and convective heat transfer to the coolant. The concentric fins further segment the heat transfer path, creating multiple parallel channels for heat to travel simultaneously. This segmentation allows heat to be dissipated through numerous routes rather than a single path, improving overall efficiency.
Solution Approach 2:
The concentric fins are nested within the cylindrical cavity of the cold plate, with the toroidal transformer positioned centrally within the fin structure. This nested arrangement maximizes the use of available space and creates multiple concentric heat transfer paths radiating outward from the transformer through the fins to the cavity walls and ultimately to the coolant.
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
Enhances heat dissipation from the toroidal transformer by minimizing thermal interface resistances and providing multiple heat transfer paths, maintaining the transformer within predefined temperature limits.
Implementation Method 1
The cold plate provides localized cooling to the components by transferring heat from the components mounted on one or both surfaces to the liquid flowing within
Implementation Method 2
transferring heat from the components mounted on one or both surfaces to the liquid flowing within
Implementation Method 3
The encapsulant is configured to facilitate radial heat transfer from the toroidal transformer
Data Source
Figure 1
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AI summary
A cold plate and a method of manufacturing the cold plate (130) involve a first side (137) with a first surface (135), and a second side (147), opposite the first side, with a second surface (145) opposite the first surface. The cold plate includes a flow channel (510) formed between the first side and the second side, and a cavity (140) integrally machined into the first surface of the first side. The cavity seats a toroidal transformer (110) and is defined by a circular outside wall (205) and a base (230) whose surface is thinner than the first surface.