Transformer Bobbin Thermal Conduction for Winding Heat Dissipation
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Solution Overview
Problem
Transformers face challenges in heat dissipation, leading to increased size and weight due to core and winding losses, which affects efficiency, safety, and miniaturization, as existing cooling methods either fail to effectively dissipate heat without adding bulk or disrupt electromagnetic flux.
Innovation Solution
A non-metallic tubular bobbin with thermally conductive material-filled openings is used to enhance heat transfer from transformer windings to the core, maintaining electromagnetic flux flow without increasing size or weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If natural cooling methods are used, then the transformer design can be simpler and less expensive, but the transformer size increases and heat dissipation effectiveness decreases
Solution Approach 1:
The patent extracts the heat dissipation function from the complex active cooling system and implements it directly into the bobbin structure itself. The bobbin includes thermally conductive paths and heat dissipation features integrated into its design, allowing heat to be conducted from the windings to the core and dissipated without requiring external cooling systems.
Solution Approach 2:
The bobbin is designed to perform its own heat dissipation function through integrated thermal management features. The thermally conductive material and heat dissipation structures within the bobbin enable it to actively manage its own thermal conditions without requiring external cooling systems, making the system self-sufficient.
2Temperature
If active cooling methods are used, then heat dissipation effectiveness improves, but the system weight increases due to additional cooling components
Solution Approach 1:
The patent merges the heat dissipation function with the bobbin structure itself. The bobbin incorporates thermally conductive material and heat dissipation features as integral parts of its design, combining the structural support function with the thermal management function into a single component, thereby eliminating the need for separate cooling systems.
Solution Approach 2:
The bobbin is designed to perform multiple functions: providing structural support for the windings, providing a mounting surface for the core, and actively managing heat dissipation. This multi-functional design eliminates the need for separate dedicated cooling components, reducing overall system weight.
3Volume of moving object
If transformer size is reduced for miniaturization, then weight and space requirements are met, but heat dissipation capability decreases and safety risks increase
Solution Approach 1:
The patent applies local quality by concentrating thermal management features at critical locations within the bobbin. The thermally conductive material is strategically positioned to maximize heat extraction from high-heat-generation areas, and heat dissipation features are located to optimize thermal pathways, ensuring effective heat management in the compact design.
4Temperature
If cooling pipes are inserted into the transformer, then heat removal capability improves, but the coupling effect between windings and core decreases and inductance is reduced
Solution Approach 1:
The patent uses the bobbin itself as an intermediary for heat transfer. Instead of inserting cooling pipes that would physically separate the windings from the core, the bobbin acts as a thermal intermediary with thermally conductive material that facilitates heat transfer from the windings to the core while maintaining the close coupling necessary for electromagnetic performance.
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 effectively dissipates heat from transformer windings, enabling smaller transformer designs while maintaining efficiency and safety, without the drawbacks of traditional cooling methods.
Implementation Method 1
a plurality of openings formed through the wall(s) from the outer surface to the inner surface, and further comprising a thermally conductive material provided in the openings
Data Source
Figure 1
Figure 2~3
AI summary
A bobbin for receiving a transformer winding, the bobbin comprising a non-metallic tubular body (10) having at least one wall (12) having an outer surface (14) onto which the transformer winding is wound, in use, and an inner surface (13) defining a passage to receive a transformer core, in use, the bobbin comprising a plurality of openings (15) formed through the wall(s) from the outer surface to the inner surface, and further comprising a thermally conductive material provided in the openings.