Transformer Insulation Air Passages for High-Voltage Heat Dissipation

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Solution Overview

Problem

High-frequency and high-voltage transformers face challenges with heat dissipation due to solid insulation methods, which hinder their efficiency and power density in power electronic transformers.

Innovation Solution

The transformer design incorporates an insulation member with air passages and conductive parts made of semi-conductive or metal materials, allowing for effective heat dissipation and even electric field distribution, reducing thermal resistance and insulation thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solid insulation material is used to insulate between high and low voltage sides, then insulation performance is improved, but heat dissipation becomes a bottleneck

Engineering Contradiction:

Improveinsulation performanceVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The solid insulation structure is segmented into multiple parts (first insulator, second insulator, third insulator) with air passages formed between them. This segmentation allows the insulation system to maintain electrical isolation while creating channels for heat dissipation, resolving the contradiction between insulation performance and thermal management.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the insulation structure are assigned different functions: solid insulator parts provide electrical insulation where needed, while air passages are created in specific locations to enable heat dissipation. This local differentiation allows simultaneous optimization of both insulation and thermal properties.

Inventive Principle:

Principle #3Local quality

2Reliability

If insulation thickness is increased to meet high voltage requirements, then insulation reliability is improved, but device size and power density decrease

Engineering Contradiction:

Improveinsulation reliabilityVSAvoiddevice size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulation system uses a composite structure combining solid insulation materials with air gaps. This composite approach provides effective electrical insulation while reducing the overall insulation thickness compared to solid insulation alone, thereby decreasing device size and improving power density.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Air passages act as intermediary elements between the high voltage and low voltage parts. These air gaps provide electrical insulation while having minimal impact on space occupation, enabling reduced insulation thickness and improved power density while maintaining insulation reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If air passages are introduced for heat dissipation, then thermal management is improved, but insulation structure complexity increases

Engineering Contradiction:

Improveheat dissipationVSAvoidinsulation structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The air passages serve multiple functions simultaneously: they provide thermal pathways for heat dissipation, maintain electrical insulation between high and low voltage parts, and contribute to the mechanical structure. This multi-functionality reduces overall system complexity despite the introduction of air passages.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The insulation structure and heat dissipation pathways are merged into a single integrated design. The air passages are formed as integral parts of the insulation member structure, eliminating the need for separate heat dissipation components and reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances heat dissipation and reduces thermal resistance by 20 times, improving the transformer's efficiency and power density while maintaining high voltage insulation requirements.

Implementation Method 1

at least one air passage is formed by the insulation member, and at least a portion of the air passage is located within a height of the high voltage part

Methodology Applied

Scientific EffectHeat dissipation: Convection

Implementation Method 2

reduces thermal resistance by 20 times

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

the first conductive part is made of a semi-conductive material... even electric field distribution

Methodology Applied

Scientific EffectElectric field distribution: Electric Field

Data Source

PatentUS11783987B2Transformer and power module including the same

Publication Date: 2023.10.10 DELTA ELECTRONICS (SHANGHAI) CO LTD

AI summary

A transformer includes an insulation member, a high voltage part, and a low voltage part, the insulation member includes a first insulator, a second insulator, and a reference plane, the high voltage part is disposed on a first side of the reference plane, the low voltage part is disposed on a second side of the reference plane, the first insulator is disposed on the reference plane, at least a portion of the second insulator is located around the high voltage part, at least one air passage is formed by the insulation member, and at least a portion of the air passage is located within a height of the high voltage part in a normal direction of the reference plane.