Transformer Winding Spacing and Heat Dissipation
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Solution Overview
Problem
Existing transformers face challenges in efficiently dissipating heat generated by the primary and secondary windings, leading to potential temperature rises due to the separation configuration not being sufficient for high heat generation scenarios.
Innovation Solution
A transformer design where the primary and secondary windings are fixed to the wall surfaces of column-shaped magnetic cores with extremely small manufacturing tolerance, ensuring a constant distance and precise inductance value, and using thermally conductive adhesives to efficiently transfer heat to the magnetic core, which is further dissipated through a heat dissipator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the primary winding and secondary winding are separated on different circuit boards, then heat dissipation is improved, but the distance between windings cannot be kept constant
Solution Approach 1:
The heat dissipation plate serves multiple functions simultaneously: it acts as a thermal management component for both windings, provides a mechanical support structure that maintains fixed spacing between the primary and secondary circuit boards, and serves as a mounting surface for the windings. This multi-functional design ensures constant winding separation while enabling effective heat dissipation.
Solution Approach 2:
The heat dissipation plate functions as a mechanical intermediary that establishes and maintains the precise spatial relationship between the primary and secondary windings. By fixing the windings to the plate at predetermined positions, the plate ensures constant distance between windings regardless of variations in circuit board positioning or manufacturing tolerances.
2Manufacturing precision
If a gap setting member is used to maintain predetermined gap, then leakage inductance is controlled, but heat dissipation efficiency is insufficient for high heat generation
Solution Approach 1:
The heat dissipation plate acts as a thermal intermediary that captures heat from the windings and efficiently transfers it to the external environment. The plate's large surface area and direct thermal contact with both windings enable it to handle high heat generation loads that would overwhelm conventional gap setting members or passive separation structures.
Solution Approach 2:
The functions of gap maintenance and heat dissipation are merged into a single integrated heat dissipation plate structure. The plate simultaneously maintains the required spacing between windings for proper leakage inductance control and provides active heat dissipation through its thermal management capabilities, eliminating the need for separate gap setting members.
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 maintains precise inductance values and efficiently dissipates heat, preventing significant temperature rises in the windings and ensuring reliable operation by maintaining the windings at a constant distance and enhancing heat transfer efficiency.
Implementation Method 1
using thermally conductive adhesives to efficiently transfer heat to the magnetic core
Implementation Method 2
which is further dissipated through a heat dissipator
Data Source
AI summary
A transformer includes a primary winding and a secondary winding, which are flat, and a magnetic core that has a middle leg that passes through the primary and secondary windings, a first core that is connected to one end along the length direction of the middle leg, and a second core that is connected to the other end along the length direction. A first wall surface on the side of the first core where the middle leg is positioned and a second wall surface on the side of the second core which faces the first wall surface are formed so as to be parallel, the primary winding is fixed to the first wall surface, the secondary winding is fixed to the second wall surface, and the distance between the primary winding and the secondary winding is kept constant.