Cooling method for planar electrical power transformer

• US 10,147,531 B2
• Filed: 04/08/2015
• Issued: 12/04/2018
• Est. Priority Date: 02/26/2015
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Rai, Rutunj, Yalamanchili, Venkat Rao, Brar, Parminder, Duco, Michael Scott
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US14/681,437
• Publication Number:
  US 20160254085A1
• Time in Patent Office: 1,336 Days
• Field of Search: 336 55- 62, 336200, 336232
• CPC Class Codes: H01F 27/18 by evaporating liquids
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/2876 Cooling cooling transformers and inductances in general H01F27/08
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00

Abstract

The present disclosure includes an electrical power transformer that may include a core and a conductor pack. A conductor pack may include a conducting layer disposed around a portion of the core, a first planar insulating layer disposed on a first side of the conducting layer, and a second planar insulating layer disposed on a second side of the conducting layer. A cooling member may be disposed adjacent to the conductor pack. A method of manufacturing an electrical power transformer may include providing a core and providing a plurality of planar conductor packs. The planar conductor packs including a plurality of planar conducting layers and a plurality of planar insulating layers. The method may include inserting a cooling member between insulating layers of adjacent ones of the plurality of planar conductor packs.

Claims

1. An electrical power transformer comprising:

a core;

a conductor pack, the conductor pack including;

a conducting layer disposed around a portion of the core;

a first planar insulating layer disposed on a first side of the conducting layer; and

a second planar insulating layer disposed on a second side of the conducting layer; and

a cooling member disposed adjacent to the conductor pack, the cooling member including a first portion and a second portion;

wherein a plane of the second portion is substantially perpendicular to a plane of the first portion.

2. The electrical power transformer of claim 1, wherein the conductor pack is a first conductor pack;

the electrical power transformer further comprises a second conductor pack; and

, the cooling member is disposed partially between the first conductor pack and the second conductor pack.

3. The electrical power transformer of claim 1, wherein the cooling member comprises a plurality of separate sections disposed at least partially around the portion of the core.

4. The electrical power transformer of claim 1, wherein the cooling member includes a hollow body at least partially filled with a liquid.

5. The electrical power transformer of claim 4, wherein the hollow body includes the first portion, the first portion is substantially planar, and the first portion extends out from the conductor pack.

6. The electrical power transformer of claim 1, wherein the cooling member includes a first section and a second section;

the first section and the second section are disposed in a common plane;

the first section is separate from the second section; and

the first section includes the first portion and the second portion.

7. The electrical power transformer of claim 2, wherein the cooling member includes a solid planar body disposed adjacent to the first conductor pack and the second conductor pack;

and, the cooling member includes a plurality of fins that extend from the solid planar body outwardly beyond the first conductor pack and the second conductor pack.

8. The electrical power transformer of claim 1, wherein the conductor pack is a first conductor pack;

and, the electrical power transformer further comprises a second conductor pack.

9. The electrical power transformer of claim 8, wherein the cooling member is a first cooling member;

the electrical power transformer further comprises a second cooling member; and

, the first cooling member and the second cooling member are both disposed partially between and in contact with the first conductor pack and the second conductor pack.

10. The electrical power transformer of claim 9, wherein the first cooling member extends from a first side of the electrical power transformer;

and, the second cooling member extends from a second side of the electrical power transformer.

11. The electrical power transformer of claim 9, wherein the first cooling member and the second cooling member each comprise a hollow body containing liquid configured to (i) be heated by heat generated by operation of the electrical power transformer, and (ii) dissipate the heat generated by operation of the electrical power transformer by cooling and/or condensing.

12. The electrical power transformer of claim 5, wherein the first portion includes a first section and a second section;

the first section and the second section are disposed on opposite sides of a projection of the core; and

the first section is separate from the second section.

13. The electrical power transformer of claim 2, wherein the first portion is substantially horizontal and the second portion is substantially vertical, wherein at least a portion of the first portion is disposed between the first conductor pack and the second conductor pack.

14. The electrical power transformer of claim 13, wherein the second portion is disposed such that the second portion is not in contact with the first conductor pack or the second conductor pack and is not in contact with the core.

15. The electrical power transformer of claim 13, wherein the second portion is in fluid communication with the first portion and the second portion includes a plurality of cooling fins.

16. An electrical power transformer comprising:

a core;

a conductor pack, the conductor pack including;

a conducting layer disposed around a portion of the core;

a first planar insulating layer disposed on a first side of the conducting layer; and

a second planar insulating layer disposed on a second side of the conducting layer; and

a cooling member disposed adjacent to the conductor pack;

wherein the cooling member is a closed system configured to provide cooling independently of external devices for causing fluid flow.

17. A method of manufacturing an electrical power transformer, the method comprising:

providing a core;

providing a plurality of planar conductor packs, the planar conductor packs including a plurality of planar conducting layers and a plurality of planar insulating layers;

providing a cooling member including a substantially horizontal planar portion and a substantially vertical planar portion; and

inserting the cooling member between insulating layers of adjacent ones of the plurality of planar conductor packs.

18. The method of claim 17, further comprising inserting at least a portion of the core into the plurality of planar conductor packs.

19. The method of claim 18, wherein the core includes a top portion and a bottom portion that are configured for independent insertion into apertures of the plurality of planar conductor packs.

20. The method of claim 17, wherein at least a portion of the substantially horizontal planar portion is disposed between the adjacent conductor packs, and the substantially vertical planar portion comprises at least one of a heat pipe and cooling fins.