Transformer Coil Layout With Insulated Heat Conduction Path
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Solution Overview
Problem
In existing transformers, the secondary coil is disposed inside the primary coil, leading to insufficient heat radiation due to inadequate insulation and heat dissipation between the coils.
Innovation Solution
A transformer design featuring a holder with through holes between the coils, where heat radiation members with higher conductivity than the holder are placed to ensure insulation and efficient heat conduction between the primary and secondary coils, improving heat radiation while maintaining insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the secondary coil is disposed inside the primary coil, then the transformer structure is compact, but heat radiation from the secondary coil is insufficient
Solution Approach 1:
The patent changes the spatial arrangement of coils from a nested configuration (secondary inside primary) to a face-to-face configuration with the holder between them. This dimensional reorganization allows both coils to have direct exposure to external environments, dramatically improving heat radiation efficiency while maintaining compactness through the thin holder structure.
Solution Approach 2:
The holder serves as an intermediary structure positioned between the primary and secondary coils. It provides electrical insulation while its through-hole design with heat radiation members enables thermal management. The holder mediates between the need for electrical isolation and the need for effective heat dissipation from both coils.
2Reliability
If the holder provides electrical insulation between coils, then insulation is ensured, but heat radiation is insufficient
Solution Approach 1:
The holder is designed as a composite structure combining electrical insulating material with integrated heat radiation members. This composite approach allows the holder to simultaneously provide electrical insulation between coils and facilitate heat dissipation through the high-heat-conductivity radiation members positioned in its through-holes.
Solution Approach 2:
The holder features localized heat radiation members positioned in through-holes at specific locations where heat dissipation is most needed. This local quality enhancement allows the insulating holder to provide targeted thermal management without compromising its overall electrical insulation function, addressing heat radiation needs only where critical.
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 effectively conducts heat from the hotter coil to the cooler coil, enhancing heat radiation and maintaining insulation, thus improving the transformer's thermal management without increasing its size.
Implementation Method 1
thermal conduction is performed between the first coil and the second coil through the heat radiation member having the higher heat conductivity than that of the holder
Implementation Method 2
a primary coil (i.e., a first coil) and a secondary coil (i.e., a second coil) are magnetically coupled in the transformer
Data Source
AI summary
A novel transformer includes a first coil, at least one secondary coil magnetically coupled with the first coil and an electrically insulating holder. The first coil and the at least one secondary coil face each other with the holder therebetween. The holder has at least one through hole at a portion sandwiched between the first coil and the at least one second coil. The transformer also includes at least one electric insulating heat radiation member disposed in the at least one through hole in contact with the first coil and the at least one second coil. The heat radiation member has a higher heat conductivity than the holder.