Transformer Cooling Device With Internal Heat-Dissipating Panel

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing cooling methods for transformers in eco-friendly vehicle battery chargers generate substantial heat, leading to increased production costs and inefficient temperature reduction, as they require additional components like molding structures and heat-dissipating panels that do not effectively lower internal core and winding temperatures.

Innovation Solution

A cooling device with a heat-dissipating panel inserted between the primary and secondary windings, thermally coupled with a heat sink, and thermal pads to enhance heat conductivity and dissipate heat from the core and windings to the exterior, reducing internal temperatures while maintaining a gap between windings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a heat-dissipating panel is installed on the outer side of the core, then the temperature of the outer side of the core is reduced, but the temperature reduction effect inside the core and windings is minimal

Engineering Contradiction:

Improvetemperature of outer side of coreVSAvoidtemperature specification compliance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The invention transitions from external heat dissipation (outer surface) to internal heat dissipation by inserting the heat-dissipating panel into the interior space between windings, directly contacting the heat-generating components in three-dimensional space

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The heat-dissipating panel acts as an intermediary thermal conduction path between the windings and the external environment, providing a direct thermal bridge from the heat-generating windings to the heat sink

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If molding methods are used to reduce heat generation, then production costs increase and manufacturing becomes more difficult

Engineering Contradiction:

Improveheat generation reductionVSAvoidmanufacturing difficulty

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The invention separates the cooling function from the structural housing by using a discrete heat-dissipating panel that can be independently manufactured and installed, rather than requiring integrated molded cooling structures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling function is extracted as a separate component (heat-dissipating panel) that can be independently optimized and manufactured, rather than being integrated into the transformer housing through complex molding processes

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If molding structures and additional components are used for cooling, then production costs increase substantially

Engineering Contradiction:

Improvetemperature reductionVSAvoidproduction cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heat-dissipating panel serves multiple functions: it acts as a thermal conduction path, a structural support for maintaining winding spacing, and a mounting surface for the heat sink, thereby reducing the need for additional specialized components

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention combines the heat dissipation function with the existing winding support structure, eliminating the need for separate cooling components and reducing overall production costs

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 solution effectively reduces heat generation and temperature within the transformer by improving thermal conductivity and dissipating heat externally, thereby meeting temperature specifications without increasing production costs.

Implementation Method 1

release heat generated from the core, the primary winding, and the secondary winding to an exterior of the transformer using heat conductance

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

thermal pads inserted between the heat-dissipating panel and the primary winding and between the heat-dissipating panel and the secondary winding, respectively, configured to increase thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

heat sink disposed, in a stacked form, at a bottom of the core

Methodology Applied

Scientific EffectHeat dissipation: Heat Sink

Data Source

PatentUS9595379B2Cooling device for transformer

Publication Date: 2017.03.14 HYUNDAI MOTOR CO LTD

AI summary

A cooling device for a transformer, capable of reducing heat generation from windings and a core, is provided. The cooling device for the transformer includes a primary winding and a second winding wound around a center part of the core and separated from each other. A heat-dissipating panel for releasing heat generated from the core, the primary winding, and the secondary winding to the exterior using heat conductance is inserted between the primary winding and the secondary winding. In addition, the heat-dissipating panel is configured to release heat using exposed edges of the primary winding and the secondary winding.