Power Transformer Cooling Assembly for Segmented Heat Dissipation
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Solution Overview
Problem
Existing power transformer assemblies for wireless charging of electric vehicles face challenges in efficiently cooling the electronic assembly, which generates high-density heat, and the magnetic assembly, which generates low-density heat, leading to inefficient heat dissipation and increased costs due to complex manufacturing processes.
Innovation Solution
The power transformer assembly incorporates a heat dissipation system with a first heat transfer portion specifically designed for the electronic assembly to efficiently remove concentrated heat through conduction and convection, and a second heat transfer portion for the magnetic assembly to manage less concentrated heat, both utilizing a coolant circuit for enhanced heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional cooling system is used for the power transformer assembly, then the structure is simple, but the heat dissipation efficiency is poor due to high heat density in the electronic assembly
Solution Approach 1:
The cooling system is segmented into a first cooling region specifically for the electronic assembly and a second cooling region for the magnetic assembly. The first cooling region includes a first heat dissipation component with higher heat transfer capability to handle the high heat density of the electronic assembly, while the second cooling region uses a different configuration for the lower heat density magnetic assembly. This segmentation allows each region to be optimized independently for its specific thermal characteristics.
Solution Approach 2:
The heat dissipation components are designed with local quality variations - the first heat dissipation component in the first cooling region has different thermal properties (higher heat transfer capability) compared to the second heat dissipation component in the second cooling region. This local differentiation ensures that each component is optimally suited for the thermal load characteristics of its specific region, improving overall heat dissipation efficiency.
2Reliability
If the electronic assembly is cooled more effectively, then the reliability improves, but the manufacturing complexity and cost increase
Solution Approach 1:
The first heat dissipation component and the second heat dissipation component are merged into a single integrated heat dissipation assembly. This unified structure reduces the number of separate components and assembly steps, simplifying manufacturing while still providing differentiated cooling for both the electronic assembly and magnetic assembly. The integration maintains the specialized cooling zones without requiring separate manufacturing processes for each cooling component.
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 solution effectively improves the overall cooling efficiency of the power transformer assembly by reducing thermal resistance and facilitating easy heat removal from both the electronic and magnetic assemblies, thereby enhancing the reliability and reducing the manufacturing complexity and costs of the assembly.
Implementation Method 1
a first heat transfer portion associated to the electronic assembly
Implementation Method 2
heat dissipation means for dissipating heat generated by the electronic assembly during their respective power transforming operation
Data Source
AI summary
The invention relates to a power transformer assembly to transform electromagnetic power of an oscillating electromagnetic field into electric power of an electric current or available electric current to charge an electric storage device or energize an electric load. The power transformer assembly includes: a magnetic assembly to receive the oscillating electromagnetic field and transform the oscillating electromagnetic field into an electric alternating current; an electronic assembly to receive the electric alternating current and transform the electric alternating current into the electric current; and a heat dissipation means for dissipating heat associated with one or more power transforming operations of the power transformer assembly, wherein the heat dissipation means includes a first heat transfer portion associated with the electronic assembly to dissipate heat generated at least by the electronic assembly.