Transformer Assembly with Liquid Cooling and Insulation
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Solution Overview
Problem
Conventional transformer designs for high-power traction applications face challenges in achieving compact size and weight reduction while ensuring high heat dissipation and effective electrical insulation, as existing solutions like vacuum-casting or resin block types fail to manage heat dissipation efficiently.
Innovation Solution
A transformer assembly featuring a cylindrical inner and outer housing filled with an insulating liquid, with integrated cooling means and a transformer core that forms a closed loop, allowing for efficient heat dissipation through convection and thermal conductivity, and incorporating support plates with earthing connectors for electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum casting or resin block solutions are used for transformer insulation, then electrical insulation is provided, but heat dissipation is insufficient and temperature control fails
Solution Approach 1:
The patent introduces an insulating liquid as an intermediary substance that simultaneously provides electrical insulation and enables efficient heat dissipation through convection. The liquid circulates between the windings and cooling channels, serving dual functions that resolve the contradiction between insulation reliability and temperature control.
Solution Approach 2:
The patent changes the physical state of the insulation medium from solid (resin block) to liquid (insulating liquid), which fundamentally alters the heat dissipation mechanism from conduction to convection. This parameter change enables superior thermal management while maintaining electrical insulation properties.
2Temperature
If oil-filled tanks with forced oil circulation are used for cooling, then heat dissipation is improved, but size and weight cannot be reduced
Solution Approach 1:
The patent merges the insulation function and cooling function into a single integrated system. The insulating liquid serves both as the insulation medium and the cooling fluid, eliminating the need for separate oil-filled tanks and forcing circulation systems, thereby reducing overall size and weight.
Solution Approach 2:
The insulating liquid naturally circulates through convection currents driven by temperature differences, eliminating the need for external forced circulation pumps and complex cooling systems. This self-service cooling mechanism reduces device complexity and weight while maintaining effective heat dissipation.
3Volume of moving object
If compact transformer design is implemented, then size reduction is achieved, but heat dissipation capacity is insufficient
Solution Approach 1:
The patent employs hydraulic principles by using liquid circulation (natural convection) for heat transfer. The insulating liquid flows through channels and around windings, efficiently removing heat from compact components without requiring large physical dimensions for heat dissipation.
Solution Approach 2:
The patent introduces three-dimensional liquid circulation pathways and multi-directional cooling channels that maximize heat dissipation surface area within a compact volume. By utilizing spatial optimization and dimensional efficiency, the design achieves high heat dissipation capacity without increasing overall transformer size.
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 enables a compact transformer with enhanced heat dissipation and electrical insulation, effectively managing temperature and size constraints in high-power applications.
Implementation Method 1
the enclosed volume of the enclosure between the cylindrical inner housing and the cylindrical outer housing is filled with an insulating liquid
Implementation Method 2
a first cooling means arranged in or at an inner surface of the outer housing to provide cooling for the at least one winding
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a transformer assembly (20), comprising: a cylindrical inner housing (21) and a cylindrical outer housing (26) partially surrounding the cylindrical inner housing (21), the cylindrical inner housing (21) and the cylindrical outer housing (26) forming an enclosure (30), wherein the enclosed volume of the enclosure (30) between the cylindrical inner housing (21) and the cylindrical outer housing (26) is filled with an insulating liquid; - at least one winding (22, 23) in the enclosed volume (30); and - a first cooling means arranged in or at an inner surface of the outer housing (26) to provide cooling for the at least one winding (22, 23).