Transformer Arrangement With Orthogonal Windings And Thermal Shell
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Solution Overview
Problem
Conventional transformers in vehicles are heavy due to their large size and weight, and they suffer from high thermal resistance and significant losses, such as hysteresis and eddy losses, which are exacerbated by their poor thermal conductivity and inefficient magnetic material utilization.
Innovation Solution
A transformer arrangement featuring a thermally conductive and magnetic shell in contact with the transformer core, allowing for improved magnetic material saturation, reduced weight, and enhanced thermal management through the shell's ability to act as a magnetic return path and cooling surface, formed from materials like ferrite, which can be easily manufactured and integrated into vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional transformer designs are used, then the transformer can perform basic power transformation, but the weight becomes excessively high and thermal resistance increases
Solution Approach 1:
The patent employs a composite structure combining magnetic core material with aluminum thermal shell. The core uses high-permeability magnetic material for efficient flux conduction, while the aluminum shell provides superior thermal conductivity (approximately 237 W/(m·K)) to dissipate heat. This composite approach allows the transformer to maintain low weight while achieving excellent thermal management, as the aluminum shell acts as both structural component and heat dissipation pathway.
Solution Approach 2:
The patent introduces a three-dimensional orthogonal winding arrangement with windings along x, y, and z axes. This spatial distribution of windings around the core enables magnetic flux to be utilized in multiple dimensions simultaneously, increasing material utilization efficiency. The orthogonal configuration allows heat to be dissipated through multiple surface areas of the thermal shell, reducing thermal resistance without increasing overall transformer weight.
2Temperature
If larger core area is utilized to decrease thermal resistance, then thermal resistance decreases, but the weight of the transformer increases
Solution Approach 1:
The aluminum thermal shell serves as an intermediary component between the magnetic core and the external environment. It provides a dedicated thermal conduction pathway that efficiently transfers heat from the core to the surrounding air or cooling systems. The shell's high thermal conductivity creates low thermal resistance without requiring an increase in core dimensions, thereby avoiding additional weight from enlarged magnetic material.
Solution Approach 2:
The patent extracts the thermal management function from the magnetic core design and implements it through a separate aluminum thermal shell. This separation allows the core to be optimized for magnetic performance while the shell is optimized for thermal conduction. The thermal shell is attached to the core, creating a hybrid structure where thermal resistance is reduced through the shell's properties rather than through increasing core area.
3Power
If magnetic material is saturated to increase power handling, then power capacity increases, but losses such as hysteresis and eddy losses increase
Solution Approach 1:
The orthogonal three-dimensional winding configuration distributes magnetic flux utilization across multiple spatial dimensions. By arranging windings along x, y, and z axes, the transformer achieves more uniform flux distribution and better material saturation across the core volume. This multi-dimensional approach increases power handling capacity while reducing localized flux concentration that would otherwise increase hysteresis and eddy losses.
Solution Approach 2:
The patent optimizes multiple parameters including the orthogonal winding geometry, core material permeability, and thermal shell thermal conductivity. By carefully selecting and coordinating these parameters, the transformer achieves efficient magnetic material utilization that maximizes power handling while minimizing losses. The thermal shell parameter (thermal conductivity) is specifically chosen to maintain optimal operating temperatures, preventing loss increase due to thermal effects.
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 configuration results in a lighter, more efficient transformer with reduced thermal resistance and lower losses, enabling higher power operation and easier thermal management, while maintaining good magnetic properties and simplifying manufacturing.
Implementation Method 1
a thermal shell (i.e. thermally conductive shell) in contact with said transformer core
Implementation Method 2
a transformer arrangement for mounting in an electrical power unit of a vehicle comprising a transformer core
Implementation Method 3
transformers, and specifically transformers in vehicles tend to induce losses (e.g. hysteresis losses or eddy losses)
Implementation Method 4
transformers, and specifically transformers in vehicles tend to induce losses (e.g. hysteresis losses or eddy losses)
Data Source
AI summary
The present disclosure relates to a transformer arrangement (1) for mounting in an electrical power unit of a vehicle. The arrangement (1) comprising a transformer core (2) and a thermal shell (3) in contact with said transformer core (2). The transformer core (2) comprises a plurality of winding portions (4) extending from a common centre portion (c1) of said core (2), along a first axis (x1), a second axis (x2) and a third axis, (x3) each axis (x1, x2, x3) being orthogonal relative to each of the other axis (x1, x2, x3). Furthermore, each winding portion (4) comprises a conductive coil arrangement (5) wound around each winding portion (4).