Transformer Shaft Fluid Channels for Potting Glue Heat Dissipation
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Solution Overview
Problem
Existing transformers face challenges in efficiently conducting heat away due to difficulties in filling gaps between the holder and core, and between coils, 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, and a third channel from the shaft part to the coil, allowing thermally conductive potting glue to fill these gaps, enhancing heat conduction performance.
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: a closed holder for structural integrity and a separate shaft part with fluid channels for heat dissipation. The shaft part wraps around the central pillar and includes first, second, and third fluid channels that allow potting glue penetration without compromising the closed holder structure.
Solution Approach 2:
The shaft part acts as an intermediary component between the closed holder and the internal components (core and coils). It provides fluid channels that serve as pathways for thermally conductive potting glue to reach interior gaps, while the closed holder maintains its structural integrity.
2Power
If the transformer is designed for high-power applications, then the power output is improved, but the heat generation increases causing heat accumulation that deteriorates reliability
Solution Approach 1:
The patent uses fluid dynamics principles by incorporating multiple fluid channels (first, second, and third channels) through the shaft part. These channels enable thermally conductive potting glue to flow into and fill interior gaps between the core, holder, and coils, establishing effective thermal conduction pathways for high-power heat dissipation.
Solution Approach 2:
The patent changes the thermal conduction parameter by introducing multi-path fluid channels that enable complete infiltration of thermally conductive material. This transforms the thermal conduction mechanism from surface-level to volumetric, significantly improving heat dissipation capability for high-power applications.
3Ease of manufacture
If thermally conductive potting glue is applied externally to the transformer, then the manufacturing process is simple, but the glue cannot fill interior gaps between holder and core or between coil layers, causing heat conduction performance to deteriorate
Solution Approach 1:
The shaft part with integrated fluid channels is prepared in advance during manufacturing. These pre-formed channels serve as built-in pathways that guide the thermally conductive potting glue into interior gaps during the encapsulation process, eliminating the need for complex post-assembly infiltration methods.
Solution Approach 2:
The shaft part's fluid channels automatically guide and distribute the thermally conductive potting glue to all required interior locations (between holder-core, holder-coils, and coil layers) during the natural encapsulation process. The structure serves its own heat dissipation needs without requiring additional manufacturing steps or equipment.
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 design enables complete infiltration of thermally conductive potting glue, effectively dissipating heat and preventing overheating, suitable for high-power applications.
Implementation Method 1
the thermally conductive potting glue can only penetrate inwards from outside the transformer, and struggles to enter the interior of the transformer... generated heat builds up inside the transformer, causing a rise in temperature that affects the reliability and performance of the transformer
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3A~3B
AI summary
The present disclosure relates to a transformer, comprising: a core, comprising a frame part and a central pillar; a coil wound on the central pillar; and a holder comprising 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. The present disclosure further relates to an on-board charger, an electric drive system, and a vehicle.