Transformer Housing Cooling Channels for Flexible Coolant Use

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing cooling systems for interphase transformers in high-current applications are limited by the choice of coolant options due to direct contact requirements, leading to inefficient heat management.

Innovation Solution

A cooling system for interphase transformers that incorporates multiple cooling channels and circuits within the housing, allowing for a wider range of coolant options and improved heat dissipation through internal and external conduits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If immersion cooling systems with direct contact are used, then heat removal effectiveness is improved, but coolant selection is limited

Engineering Contradiction:

Improveheat removal effectivenessVSAvoidcoolant selection

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The cooling system is segmented into separate functional components: cooling channels are integrated into the housing structure rather than requiring direct immersion of coolant in the transformer windings. This segmentation allows the coolant to flow through dedicated channels, decoupling the cooling function from the electrical components while maintaining effective heat removal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The housing with integrated cooling channels acts as an intermediary between the heat-generating transformer components and the coolant. The housing structure mediates the thermal transfer, allowing indirect cooling that expands coolant options beyond those suitable for direct contact with electrical windings.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple cooling channels and circuits are integrated into the housing, then coolant options and heat dissipation are improved, but device complexity increases

Engineering Contradiction:

Improvecoolant optionsVSAvoidcooling system structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cooling channels are merged with the housing structure itself, combining the structural support function with the thermal management function. This integration reduces the number of separate components needed, as the housing serves dual purposes: mechanical enclosure and heat dissipation pathway.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing is designed with multi-functionality, serving both as the structural enclosure for the transformer and as the coolant flow pathway. This universal design allows the same component to fulfill multiple roles, reducing overall system complexity despite the sophisticated cooling capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If cooling channels are integrated into the housing, then direct contact cooling is eliminated, but manufacturing complexity increases

Engineering Contradiction:

Improvecoolant selectionVSAvoidhousing manufacturing

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The cooling channels are designed with standardized cross-sectional dimensions and uniform wall thicknesses, maintaining consistent geometric parameters throughout the housing structure. This standardization of parameters simplifies the manufacturing process, allowing conventional machining or molding techniques to produce the integrated cooling channels without excessive complexity.

Inventive Principle:

Principle #35Parameter changes

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 removal capabilities, enabling efficient temperature control and broader coolant selection without direct contact, thus maintaining transformer performance.

Implementation Method 1

As the current flows through the windings, heat is produced

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

a flow of coolant is placed in direct contact with the windings

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP4006925B1Cooling system for a transformer and a method of cooling a transformer

Publication Date: 2026.03.18 HAMILTON SUNDSTRAND CORP

Figure 1
Figure 2
Figure 3

AI summary

A transformer (30) includes a housing (40) having a base wall (54), a first side wall (56), a second side opposing wall (58), a third side wall (60) joining the first side wall and the second side wall at a first end and including a first cooling channel (78), and a fourth side wall joining the first side wall and the second side wall at a second end. The first, second, third, and fourth side walls collectively define an interior portion. A cover (66;120) extends across each of the first side wall the second side wall, the third side wall, and the fourth side wall. A cooling system includes the first cooling channel (78) disposed in the third side wall, a second cooling channel (80) disposed in the fourth side wall, and a third cooling channel (82) disposed in the cover.