Winding Element With Integrated Cooling Channels
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Solution Overview
Problem
Existing transformer arrangements face challenges in cooling electrical components, particularly in resistance welding systems, due to heat-induced mechanical property degradation, corrosion risks, and inefficient heat dissipation, which limits power output and increases costs.
Innovation Solution
A winding element with threaded fastening means and internal cavities for cooling fluid circulation, allowing for robust and stable attachment to carrier components without heat addition, combined with a design that includes E-shaped or C-shaped configurations for improved thermal conductivity and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If copper pipes are welded to carrier components to improve mechanical strength, then mechanical strength is improved, but material properties are degraded and oxidation occurs requiring time-consuming cleaning
Solution Approach 1:
The invention divides the winding element into a modular design where the carrier component and cooling channels are integrated as a single unit. This segmentation eliminates the need for separate welding operations to attach cooling pipes to carrier components, thereby avoiding the time-consuming cleaning process while maintaining structural integrity through precision-machined interfaces
Solution Approach 2:
The carrier component and cooling channels are merged into a single integrated structure. The cooling channels are directly formed within the carrier component itself, eliminating the need for separate welding operations to attach external cooling pipes, thus avoiding material degradation and oxidation while maintaining mechanical strength
2Temperature
If cooling fluid is conducted through copper pipes to cool the winding, then cooling efficiency is improved, but mechanical strength is weakened
Solution Approach 1:
The cooling channels are merged directly into the carrier component structure, creating a unified load-bearing and cooling system. This integration allows the carrier component to maintain full mechanical strength while simultaneously providing efficient cooling pathways, eliminating the need for separate thin-walled copper pipes that would compromise structural integrity
Solution Approach 2:
The carrier component is designed as a composite structure combining load-bearing material with integrated cooling channels. This composite design allows the main body to provide mechanical strength while embedded channels provide cooling functionality, avoiding the need to use weaker materials for cooling purposes
3Temperature
If rectifier diodes are cooled using cooling bodies with direct contact, then cooling effectiveness is improved, but corrosion occurs requiring additional sealing
Solution Approach 1:
The carrier component serves as an intermediary between the cooling fluid and the rectifier diodes. Cooling fluid flows through channels in the carrier component, which then conducts heat away from the diodes through controlled thermal contact. This intermediary approach provides effective cooling while preventing direct corrosive contact between the cooling fluid and diode components
Solution Approach 2:
The cooling function is extracted from direct contact with electronic components. Instead of allowing cooling fluid to directly contact rectifier diodes, the cooling function is separated into dedicated channels within the carrier component, eliminating corrosion risks while maintaining thermal management effectiveness
4Ease of manufacture
If conventional cooling designs with small cooling surfaces are used, then assembly is simplified, but power output is limited due to insufficient heat dissipation
Solution Approach 1:
The cooling solution transitions from two-dimensional surface cooling to three-dimensional volumetric cooling. Multiple cooling channels are distributed throughout the volume of the carrier component, dramatically increasing the cooling surface area available for heat dissipation. This volumetric approach enables high power output while maintaining assembly simplicity through the integrated monolithic structure
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
Enhances cooling efficiency, increases electrical output, simplifies assembly, and reduces manufacturing costs by eliminating the need for welding or soldering, while preventing material alteration and corrosion, thus achieving a more economical and effective cooling solution.
Implementation Method 1
at least one interior cavity for receiving a cooling fluid is provided. The cooling fluid, in particular water, may circulate inside the winding element and thereby easily dissipate the heat that is produced
Implementation Method 2
good thermal conductivity may be attained by using an advantageous, solid design of the winding element
Data Source
AI summary
The invention relates to a winding element (200) for conducting current, forming a component of a coil winding (132, 133; 408, 409), especially of a (welding) transformer winding, comprising fixing means (205) for fixing the winding element (200) to a carrier component (402, 403, 404). The invention also relates to a transformer arrangement (100; 600), especially a welding transformer arrangement, comprising a primary winding (132; 408) and a secondary winding (133; 409), the primary winding (132; 408) and/or secondary winding (133; 409) comprising at least one winding element (200) according to the invention.