Transformer Holder Fluid Channels for Potting Glue Heat Dissipation
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Solution Overview
Problem
Existing transformers face challenges in heat dissipation due to thermally conductive potting glue's difficulty in penetrating gaps between the holder and core, as well as between coil layers, leading to heat accumulation and reduced reliability in high-power applications.
Innovation Solution
The transformer design incorporates multiple fluid channels, including a first channel between the holder's shaft part and the core, a second channel through the shaft part to the coil, and a third channel from the outside to the shaft part-coil interface, allowing thermally conductive potting glue to fully infiltrate and fill these gaps, enhancing heat conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the transformer uses a closed holder structure with tightly wound coils, then the mechanical strength and structural integrity are improved, but the thermally conductive potting glue cannot penetrate into the interior gaps, causing heat dissipation performance to deteriorate
Solution Approach 1:
The holder is segmented into multiple parts (first holder part, second holder part, third holder part) that can be assembled in sequence, creating accessible gaps for potting glue injection while maintaining overall structural integrity. The shaft part is divided into sections with fluid channels that enable controlled access to interior regions.
Solution Approach 2:
The patent introduces fluid channels as intermediary pathways within the holder structure. These channels act as mediators that guide the thermally conductive potting glue from the exterior into the interior gaps between coils and core, enabling heat dissipation without compromising the closed structural design.
2Power
If the transformer operates at high power, then the power handling capability is improved, but heat accumulation increases, causing reliability to deteriorate
Solution Approach 1:
The patent uses fluid dynamics principles by designing the holder with multiple fluid channels that allow thermally conductive potting glue to flow through the transformer interior. This hydraulic approach ensures complete filling of gaps for optimal thermal conduction, enabling high-power operation without heat accumulation.
Solution Approach 2:
The patent employs composite material strategy by combining the holder structure with thermally conductive potting glue. The glue-filled gaps create a composite thermal pathway that efficiently conducts heat from the core and coils to the holder exterior, maintaining reliability during high-power operation.
3Reliability
If thermally conductive potting glue is used to fill gaps, then heat conduction performance is improved, but the difficulty of filling interior gaps increases, worsening the manufacturing complexity
Solution Approach 1:
The holder structure is pre-designed with integrated fluid channels during manufacturing. This preliminary action ensures that the pathways for potting glue injection are already in place, eliminating the need for complex post-assembly modifications and simplifying the manufacturing process while ensuring complete gap filling.
Solution Approach 2:
The patent transitions from attempting to fill gaps from a single exterior direction to creating multi-dimensional pathways through the holder. The fluid channels provide three-dimensional access routes that allow potting glue to reach previously inaccessible interior regions, simplifying the filling process while achieving complete coverage.
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 ensures efficient heat conduction within the transformer, preventing overheating and improving performance in high-power scenarios by ensuring thermally conductive potting glue fills all gaps, thus enhancing reliability and power handling capabilities.
Implementation Method 1
the coils and core of a transformer generate a large amount of heat during sustained operation. A known method of enhancing the heat dissipation capacity of a transformer is to encapsulate the transformer in thermally conductive potting glue, so that heat generated by the transformer is efficiently conducted to an external heat dissipation system.
Data Source
AI summary
A transformer includes a core having a frame part and a central pillar; a coil wound on the central pillar; and a holder having a shaft part, the shaft part wrapping the central pillar so that the shaft part is located between the coil and the central pillar. A first fluid channel for thermally conductive potting glue to flow through is provided between the shaft part and the central pillar, and the shaft part is provided with a second fluid channel allowing the thermally conductive potting glue to flow through the shaft part from the first fluid channel to the coil. A n on-board charger, an electric drive system, and a vehicle may implement the transformer.