Transformer Plate Windings Current Withstanding Heat Dissipation
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Solution Overview
Problem
Conventional transformer structures prioritize high power density but fail to effectively withstand large currents and efficiently dissipate heat, leading to reduced efficiency and the need for external heat dissipation devices.
Innovation Solution
A transformer structure incorporating a circuit board with a rectification filter circuit, current guide and bearing plates, and plate windings that are electrically connected to enhance current withstanding capability and provide increased heat dissipation through plate materials and strategically positioned heat sinks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional integrated transformer structures are used to achieve high power density, then power density is improved, but current withstanding capability deteriorates
Solution Approach 1:
The invention divides the winding structure into multiple segments: plate windings for high-voltage sections and wire windings for low-voltage sections. This segmentation allows each type to be optimized for its specific function - plate windings provide large surface area for current distribution while wire windings provide flexibility and ease of connection, thereby resolving the contradiction between power density and current withstanding capability.
Solution Approach 2:
The invention uses composite winding structures combining plate windings and wire windings. The plate windings are made of laminated copper plates with insulating layers, while wire windings use traditional insulated copper wires. This composite approach leverages the advantages of both materials - the high current carrying capacity and heat dissipation of plates and the flexibility and ease of connection of wires - to achieve both high power density and strong current withstanding capability.
2Power
If conventional integrated transformer structures are used to achieve high power density, then power density is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The winding structure is segmented into plate windings and wire windings, where plate windings provide large surface area for heat dissipation. The plate structure with its extended surface area enables more efficient heat transfer to the surrounding environment, preventing heat accumulation while maintaining high power density.
Solution Approach 2:
The invention introduces heat sinks as intermediary heat dissipation devices that are thermally coupled to the plate windings. These heat sinks act as mediators between the transformer windings and the environment, providing an efficient heat transfer path that enables high power density operation without excessive temperature rise.
3Temperature
If external heat dissipation devices are added to improve heat dissipation, then heat dissipation capability is improved, but power density deteriorates
Solution Approach 1:
The invention merges the heat dissipation function directly into the winding structure by using plate windings that serve both as electrical conductors and heat dissipation surfaces. This integration eliminates the need for separate heat dissipation devices, maintaining high power density while providing efficient heat dissipation through the plate structure's large surface area.
Solution Approach 2:
The plate windings perform multiple functions simultaneously: they serve as electrical conductors for power transmission and as heat dissipation surfaces due to their large surface area. This multi-functionality eliminates the need for dedicated heat dissipation devices, thereby maintaining high power density while achieving effective heat dissipation.
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 significantly improves current withstanding capacity and heat dissipation, maintaining high power density while preventing excessive temperature rise, thus enhancing overall transformer efficiency.
Implementation Method 1
The two wire windings are wound on the transformer iron core to form a primary side of the transformer, respectively. The two plate windings are wound for at least one turn on the transformer core and fixed on the circuit board, and form a secondary side of the transformer.
Implementation Method 2
The two plate windings, the two wire windings and the transformer iron core form a transformer. The two plate windings are electrically connected to the current guide plate and the current bearing plate to jointly withstand the current flowing through the transformer structure.
Implementation Method 3
two plate windings, the two wire windings and the transformer iron core form a transformer. The two plate windings are electrically connected to the current guide plate and the current bearing plate to jointly withstand the current flowing through the transformer structure
Data Source
AI summary
A transformer structure includes a circuit board, a current bearing plate, a transformer iron core, two wire windings and two plate windings. The circuit board is provided with a rectification filter circuit at least including a filter inductor, a filter capacitor and a rectification switch. The filter inductor is formed by a current guide plate on the circuit board and an inductor iron core sleeved on the current guide plate. The current bearing plate is stacked on the circuit board and electrically connected to the rectification filter circuit. The transformer iron core is on the circuit board. The two plate windings are plate materials, and are wound for at least one turn on the transformer iron core and fixed on the circuit board. The plate windings are electrically connected to the current guide plate and the current bearing plate to jointly withstand a current flowing through the transformer structure.