Transformer Radiator Undulating Fin Sealed Structure
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Solution Overview
Problem
Existing transformer radiators face challenges such as high cost, leakage issues due to open fins, and difficulty in pressure testing and galvanization, particularly with pressed steel and corrugated fin types.
Innovation Solution
A transformer radiator featuring a single component heat exchange fin with a continuously undulating profile, sealed metal sheet portions, and transverse manifolds that allow for sealed connections and pressure testing, enabling cost-effective manufacturing and improved structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressed steel panels are used to construct the radiator, then the radiator structure is rigid and durable, but the manufacturing cost increases due to the necessity of handling, aligning, and welding individual panels with reinforcing rods
Solution Approach 1:
The patent combines multiple discrete pressed steel panels into a single monolithic 3D-formed structure. The radiator body is formed as one continuous piece with integrated fins and internal passages, eliminating the need for separate panel assembly, alignment, and reinforcement operations. This merging of components directly reduces manufacturing cost while maintaining structural rigidity through the integrated 3D formation process.
2Temperature
If corrugated fins are used to increase heat dissipation surface area, then heat exchange efficiency improves, but leakage risk increases due to open fins requiring extensive welding around the transformer tank wall
Solution Approach 1:
The patent employs thin-walled 3D-formed structures with integrated fins that are sealed as a single component. The fin structures are enclosed within the monolithic radiator body, creating sealed internal passages for oil flow. This eliminates the open fin configuration that requires extensive welding to the tank wall, thereby reducing leakage risk while maintaining high heat dissipation efficiency through the 3D-formed surface geometry.
3Ease of manufacture
If traditional radiator structures with open fins are used, then manufacturing is simpler, but pressure testing for leaks and galvanization become impossible
Solution Approach 1:
The patent integrates the fin structures and internal passages into a single sealed monolithic component. This closed, enclosed structure allows for pressure testing to detect leaks before installation, as the entire radiator body can be pressurized and inspected. The same integrated structure also enables galvanization by providing a continuous surface that can be coated uniformly, unlike open fin configurations.
4Strength
If multiple discrete elements are used to form radiator cells, then structural reinforcement is achieved, but device complexity increases due to the number of components requiring assembly
Solution Approach 1:
The patent consolidates multiple discrete radiator cells and reinforcing elements into a single 3D-formed monolithic structure. The reinforcement features are integrated directly into the formation process of the single piece, eliminating the need for separate reinforcing rods and multiple panel assemblies. This reduces device complexity by transforming a multi-component assembly into a single-component structure while maintaining or enhancing structural strength.
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 solution allows for cost-effective mass production, reduced leakage risk, ease of installation, and enhanced structural strength, along with the ability to be pressure tested and galvanized, offering improved heat dissipation and aesthetic appeal compared to traditional radiators.
Implementation Method 1
a transformer radiator including: an inlet manifold; an outlet manifold; and a heat exchange fin extending between and connected to the inlet and outlet manifolds
Implementation Method 2
dispatching heat from the oil to the ambient air
Implementation Method 3
the heat exchange fin is provided by a single component having a continuously undulating profile
Implementation Method 4
The single component of the heat exchange fin may comprise a pair of metal sheet portions sealed to one another peripherally
Data Source
AI summary
This invention concerns a transformer radiator. The radiator includes an inlet manifold, an outlet manifold and a heat exchange fin. The find extends between and is connected to the inlet and outlet manifolds. The heat exchange fin defines at least one oil flow passage to convey transformer oil, which, in use, enters the radiator through the inlet manifold, to the outlet manifold. The heat exchange fin is further provided by a single component having a continuously undulating profile and the manifolds extend transversely to the turns of the undulating profile.