Transformer Cooling via Air Channeling Structure

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Solution Overview

Problem

Conventional transformer cooling systems in aircraft rely on thermally conductive potting materials that add significant weight without providing adequate cooling or structural support, necessitating a solution that eliminates the need for these materials while maintaining cooling efficiency and structural integrity.

Innovation Solution

A cooling system comprising a fan duct with a fan and a housing that encloses a transformer assembly, featuring an air channeling structure between the transformer and the fan duct, allowing airflow to pass through gaps between the transformer's core sections, thereby eliminating the need for potting material and providing structural support through lightweight components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermally conductive potting material is used to cool the transformer, then cooling capacity is provided, but weight increases considerably

Engineering Contradiction:

Improvecooling capacityVSAvoidweight of transformer assembly

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The patent removes the potting material entirely from the transformer assembly, extracting the harmful element (weight) while preserving the cooling function through an alternative air-based cooling system with channels that direct airflow across the transformer core

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs air flow through dedicated cooling channels as a pneumatic cooling mechanism, replacing the solid conductive potting material with a fluid (air)-based heat transfer system that achieves cooling without added weight

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Temperature

If thermally conductive potting material is used to cool the transformer, then cooling is provided, but structural support is not adequately achieved

Engineering Contradiction:

Improvecooling capacityVSAvoidstructural support

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent extracts the dual function of potting material (cooling + structural support) and separates these functions: cooling is achieved through air channels while structural support is provided by the housing and mounting structure

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The housing structure serves multiple functions simultaneously: it provides structural support for the transformer assembly and incorporates integrated cooling channels that guide airflow, eliminating the need for potting material to fulfill both roles

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If potting material is used to provide thermal conduction, then thermal interface is achieved, but the added weight is undesirable

Engineering Contradiction:

Improvethermal interfaceVSAvoidweight of transformer assembly

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The patent replaces solid thermal conduction through potting material with pneumatic heat transfer using air flow through channels, achieving thermal interface function without the weight penalty of solid materials

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The patent substitutes the mechanical thermal conduction system (potting material contact) with a fluid dynamics-based system (air flow through channels), replacing direct solid-to-solid thermal contact with convective heat transfer

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution effectively cools the transformer without the weight of potting material, achieving efficient heat transfer and structural support, resulting in a lighter and more efficient cooling system for aircraft transformers.

Implementation Method 1

Methodology Applied

Scientific EffectForced Convection: Forced Convection

Implementation Method 2

A cooling airflow path passes through the air channeling structure and between the cores of the transformer

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS8368497B2Transformer assembly with enhanced air cooling

Publication Date: 2013.02.05 HAMILTON SUNDSTRAND CORP

AI summary

A cooling system for a transformer comprises a fan duct and a housing which together enclose an interior space. A transformer located in the interior space is mounted on the fan duct, and has a plurality of core sections surrounded by windings and separated by gaps. An air channeling structure is located between the transformer and the fan duct. A cooling airflow path extends through the air channeling structure, and between core sections of the transformer.