Integrated Transformer Winding Support With Polymer Coolant Channels
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Solution Overview
Problem
Conventional support structures for power transformer windings are complex, costly, and made from heavy, anisotropic cellulose-based materials that require multiple parts, leading to inefficiencies in mechanical and electrical properties, and increased size and weight.
Innovation Solution
A single, integrated support structure formed from polymer materials using additive manufacturing, combining compression, insulation, and coolant flow functions, reducing the number of parts and enhancing mechanical, electrical, and thermal properties with optimized shapes and internal cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-part support structures made from cellulose-based materials are used, then mechanical stability and electrical insulation are provided, but the device complexity, weight, and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate support structure components (press plates, spacers, insulators, coolant distributors) into a single integrated support structure made from polymer material. This merging eliminates the need for multiple discrete parts that were previously assembled together, reducing assembly complexity while maintaining all required functions of mechanical support, electrical insulation, and coolant distribution
Solution Approach 2:
The integrated support structure performs multiple functions simultaneously: it provides mechanical support and compression force distribution, electrical insulation between windings and coolant flow paths, and structural stability. This multi-functional design replaces several specialized components with a single universal structure that accomplishes all tasks
2Reliability
If conventional multi-part support structures are used, then the required functions are fulfilled, but the weight and size of the power transformer increase
Solution Approach 1:
By merging multiple cellulose-based components into a single polymer structure, the overall weight is reduced due to the lighter polymer material and elimination of redundant components. The integrated design removes unnecessary material while preserving all structural support functions
Solution Approach 2:
The patent changes the material parameter from heavy cellulose-based materials to lighter polymer materials, achieving weight reduction while maintaining structural integrity. This material substitution allows the support structure to provide equivalent mechanical support with significantly reduced mass
3Ease of manufacture
If conventional cellulose-based materials are used, then manufacturing experience is available, but the manufacturing process is more complex and costly
Solution Approach 1:
The integrated support structure can be manufactured as a single piece using additive manufacturing or other forming processes, eliminating the need for assembling multiple pre-manufactured components. This reduces manufacturing steps, labor requirements, and assembly time, significantly improving productivity despite using newer polymer materials
4Reliability
If conventional support structures are used, then adequate insulation is provided, but the dielectric permittivity is higher and thermal class is lower
Solution Approach 1:
The patent changes the material parameters by selecting polymer materials with lower dielectric permittivity and higher thermal stability compared to conventional cellulose-based materials. This parameter optimization enables the support structure to function as insulation with higher thermal class, allowing operation at elevated temperatures while maintaining electrical insulation performance
Data Source
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AI summary
The present disclosure relates to a support structure (10) for at least one winding (24) of an inductive device, comprising a press structure (11) configured to transfer and distribute an compression force from a holding structure to the at least one winding (24), an insulator structure (12) configured to electrically insulate the holding structure from the at least one winding (24), and a coolant flow structure (13) configured to guide and distribute a flow of a liquid coolant to or from different parts of the at least one winding (24). The press structure (11), the insulator structure (12) and the coolant flow structure (13) are formed as one integrated part comprising a polymer material. The integrated part comprises a plurality of orifices (14, 15) for passage of the liquid coolant from a first side (16) facing the holding structure to a second side (17) facing the at least one winding (24). The present disclosure further relates to a power transformer (20) comprising such a support structure (10) and a method for manufacturing a support structure (10).