Hybrid Transformer Cooling with Housing Fluid Channels
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Solution Overview
Problem
Conventional thermal management systems for transformer assemblies are inadequate in efficiently managing waste heat generated by transformer windings and cores, leading to potential electrical component failure and reduced reliability under extreme conditions.
Innovation Solution
A hybrid cooling system combining conductive cooling through potting material and convective cooling via a fluid circuit with directed fluid spray or jet impingement, utilizing a fluid circuit within the transformer housing to manage heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional physical heat sink systems with potting material and cold plates are used, then heat dissipation is achieved, but thermal management efficiency is insufficient under extreme conditions
Solution Approach 1:
The patent employs a fluid spray system where cooling fluid is pumped through channels in the housing walls and sprayed onto the windings and core surfaces. This hydraulic cooling approach directly contacts the heated components, efficiently removing heat and maintaining lower operating temperatures, thereby improving reliability under extreme conditions compared to conventional passive heat sinks.
Solution Approach 2:
The housing walls are segmented with integrated fluid channels that distribute cooling fluid to multiple spray outlets positioned at strategic locations. This segmentation allows targeted cooling of different hot spots on the windings and core, optimizing thermal management efficiency across the entire transformer assembly.
2Power
If higher power dissipation is achieved in smaller volumes, then power density increases, but thermal management becomes more challenging
Solution Approach 1:
The patent merges the structural housing with the cooling system by integrating fluid channels directly into the housing walls. This combination eliminates the need for separate cold plates and mounting hardware, reducing overall volume while maintaining effective cooling. The spray system directly targets the windings and core, enabling high power dissipation in a compact form factor with controlled peak temperatures around 182°C.
3Reliability
If fluid spray cooling is applied directly to windings, then heat transfer efficiency improves, but erosion of winding surfaces occurs
Solution Approach 1:
The patent applies an erosion-resistant coating to the winding surfaces before implementing the spray cooling system. This protective layer acts as a cushion against the erosive effects of the cooling fluid spray, allowing direct contact cooling to proceed effectively while preserving the structural integrity of the winding surfaces over time.
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 hybrid cooling system effectively reduces winding and core temperatures, enhancing transformer reliability, enabling higher power dissipation and reduced weight, while maintaining components within safe operating temperatures.
Implementation Method 1
heat is transferred to the fluid from at least one of the core and the at least one winding
Implementation Method 2
directing the cooling fluid to flow through a fluid circuit defined within at least one wall of a housing
Implementation Method 3
The opening can be configured to spray fluid onto an outer surface of the at least one winding within the interior of the housing
Data Source
Figure 1~2
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Figure 5~6
AI summary
A transformer assembly includes a housing (102), a core (104) within an interior (103) of the housing, and at least one winding (106) positioned around the core. The at least one winding and the core are mounted to the housing with potting material (108). At least a portion of a fluid circuit (110) is defined within at least one wall (112b) of the housing. The at least the portion of the fluid circuit is defined through an opening in the at least one wall of the housing in fluid communication with the interior of the housing. A transformer assembly includes a housing, a core within an interior of the housing, at least one winding positioned around the core, and a fluid circuit defined at least partially within at least one wall of the housing being configured such that heat is transferred to the fluid from at least one of the core and the at least one winding.