Transformer Thermal Dissipation via Water-Cooling Metal Block
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Solution Overview
Problem
High-power automotive power supply modules face challenges in achieving high thermal efficiency and power conversion efficiency within limited volume, leading to potential overheating and reliability issues.
Innovation Solution
The design incorporates a transformer with enhanced heat dissipation capabilities by using a magnetic component with enlarged thermal dissipation areas, including annular metal plates with increased heat-dissipating ends and a water-cooling metal block, to effectively dissipate heat and improve power conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the power supply module operates at high power, then the power conversion efficiency needs to be improved, but the temperature increases causing thermal breakdown and reduced efficiency
Solution Approach 1:
The patent transitions from conventional planar heat dissipation to three-dimensional radial heat dissipation by positioning cooling channels around the magnetic component in multiple directions. This spatial dimensionality change enables heat to be dissipated simultaneously from multiple surfaces, dramatically improving thermal management efficiency without increasing the module's footprint.
Solution Approach 2:
The patent introduces a cooling medium (water or coolant) as an intermediary substance that absorbs heat from the magnetic component through dedicated cooling channels. This intermediary transfers thermal energy from the high-power components to the surrounding environment, enabling continuous high-power operation without thermal runaway.
2Loss of energy
If the cooling efficiency is improved in a limited volume, then the power conversion efficiency increases, but the module volume must be controlled within predetermined limits
Solution Approach 1:
The patent embeds cooling channels directly within the magnetic component structure itself, nesting the thermal management system inside the power conversion component. This nested arrangement eliminates the need for separate external cooling apparatus, achieving high cooling efficiency while maintaining compact module volume within predetermined limits.
Solution Approach 2:
The magnetic component serves dual functions: power conversion and heat dissipation. The same structural elements that generate magnetic fields for power transformation also provide pathways for heat removal, eliminating the need for dedicated cooling components and reducing overall module volume.
3Loss of energy
If the thermal design is optimized for high-power operation, then the power conversion efficiency improves, but the device complexity increases
Solution Approach 1:
The patent merges the power conversion function and thermal management function into a single integrated structure. The magnetic component's body simultaneously performs electromagnetic transformation and serves as the heat dissipation pathway, eliminating the need for separate cooling systems and reducing overall device complexity despite high-power requirements.
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 enhances the heat-dissipation ability of the power supply module, achieving a compact and reliable automotive power supply with improved thermal performance and power conversion efficiency.
Implementation Method 1
a water-cooling metal block to effectively dissipate heat
Implementation Method 2
water-cooling metal block to effectively dissipate heat
Implementation Method 3
The at least one secondary winding has a first section and a second section... At least a portion of the at least one primary winding is located between the first section and the second section
Data Source
AI summary
A transformer includes two first cores, a primary winding and a secondary winding. The secondary winding has a first section and a second section. The first section has a first outlet end, a second outlet end, and a first connection end, wherein the first outlet end and the second outlet end are located at a side of the first section, the first connection end is located at an opposite side of the first section. The second section has a third outlet end, a fourth outlet end, and a second connection end. The third outlet end and the fourth outlet end are located at a side of the second section, and the second connection end is located at an opposite side of the second section. A portion of the primary winding is located between the first section and the second section of the secondary winding.