Transformer Winding Gaps for Conduction-Convection Cooling
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Solution Overview
Problem
Transformer arrangements in power supplies for electrical energy storage modules face challenges in thermal management, particularly when generating high-current or high-voltage electrical pulses, which can lead to premature failure due to inadequate heat dissipation.
Innovation Solution
The arrangement embeds a magnetic element and windings in a thermally conductive material while maintaining gaps for air flow, allowing for both conduction and convection cooling, thereby enhancing thermal management and preventing premature failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the transformer components are embedded in thermally conductive material, then heat dissipation is improved, but air flow for convection cooling is blocked
Solution Approach 1:
The patent applies local quality by creating gaps in specific locations where windings are most prone to overheating, while embedding other components in thermally conductive material. The gaps are strategically positioned to allow air flow for convection cooling in critical areas, while maintaining thermal conduction in less critical regions. This resolves the contradiction by providing localized thermal management tailored to the specific thermal requirements of different transformer components.
Solution Approach 2:
The patent uses composite material structures by combining thermally conductive material with air gaps to create a hybrid thermal management system. The thermally conductive material provides conduction cooling where needed, while the air gaps enable convection cooling in other areas. This composite approach allows simultaneous utilization of both thermal conduction and convection mechanisms to manage heat effectively without the limitations of using either method alone.
2Temperature
If thermally conductive material is used for embedding, then thermal management is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the thermally conductive material with integrated gaps before embedding the transformer components. This pre-formed structure with built-in cooling channels and gaps simplifies the assembly process, as the thermal management features are already in place rather than requiring complex post-assembly modifications. This resolves the manufacturing complexity issue by preparing the thermal management structure in advance.
Solution Approach 2:
The patent uses composite material structures by combining thermally conductive material with air gaps to create a hybrid thermal management system. The thermally conductive material provides conduction cooling where needed, while the air gaps enable convection cooling in other areas. This composite approach allows simultaneous utilization of both thermal conduction and convection mechanisms to manage heat effectively without the limitations of using either method alone.
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 manages heat transfer and cooling, ensuring high reliability and adaptability to different applications by optimizing the balance between thermally conductive material embedding and air flow within the gaps, thus preventing thermal-related issues in transformer systems.
Implementation Method 1
transfer of heat, which may have been generated by the arrangement when in use, away from the arrangement may be facilitated
Implementation Method 2
at least a portion of the plurality of turns of the second winding and/or the plurality of turns of the first winding, and possibly a portion of the magnetic element, may be cooled by means of convection as air flows in the at least one gap
Data Source
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AI summary
An arrangement (10, 20, 30) id disclosed, comprising a magnetic element (10) and at least a first winding (10) and a second winding (20), wherein each of the first winding (20) and the second winding (30) is wound in a plurality of turns (41, 42, 43, 44, 51, 52, 53, 54) around at least a portion of the magnetic element (10), and wherein at least a part or portion of the plurality of turns (51, 52, 53, 54) of the second winding (30) wound around the at least a portion of the magnetic element is arranged in spaced relation to at least a part or portion of the plurality of turns (41, 42, 43, 44) of the first winding (20) wound around the at least a portion of the magnetic element (10), thereby defining at least one gap (61, 62) between the at least a part or portion of the plurality of turns (51, 52, 53, 54) of the second winding (30) and the at least a part or portion of the plurality of turns (41, 42, 43) of the first winding (20). At least the magnetic element (10) and the first winding (20) and the second winding (30) define an assembly of the arrangement (10, 20, 30), and wherein at least a part or portion of the assembly is arranged so as to be embedded in a thermally conductive material (70) and such that at the same time a flow of air in the at least one gap (61, 62) is permitted.