Patent Publication Number: US-2018053593-A1

Title: Transformer embedded with thermally conductive member

Description:
RELATED APPLICATIONS 
     This application claims priority to Taiwan Application Serial Number 105126797, filed Aug. 22, 2016, which is herein incorporated by reference. 
     BACKGROUND 
     Technical Field 
     The present disclosure relates to a transformer. 
     Description of Related Art 
     Transformers are commonly used for energy transfer and conversion. During operation, a transformer will heat up due to many factors. For example, the current flowing through the winding of the transformer will cause the resistive heating of the conductor of the transformer, and the heat is dissipated by the conductor. Specifically, the induced eddy currents will circulate within the iron core of the transformer, thereby causing the resistive heating. The heat in the iron core produced by that the eddy currents will then be transferred to other components of the transformer. In addition, the residual DC current in the transformer will also cause the transformer to heat up. Therefore, the operation of the transformer is often accompanied with the heating of the transformer. 
     A conventional approach of cooling a transformer is forcibly cooling by air (e.g., by using a fan). However, the approach is not effective to efficiently dissipate the heat produced during the operation of the transformer. Therefore, the difference between the temperature of the transformer in operation and the room temperature is still too large, which seriously affects the performance of the transformer. 
     Accordingly, how to provide a transformer to solve the aforementioned problems becomes an important issue to be solved by those in the industry. 
     SUMMARY 
     An aspect of the disclosure is to provide a transformer embedded with one or more thermally conductive members to effectively reduce the temperature in operation. 
     According to an embodiment of the disclosure, a transformer includes an iron core, at least one winding, and at least one first thermally conductive member. The winding is wound onto the iron core. The winding has a plurality of wiring layers. The thermally conductive member is thermally connected between adjacent two of the wiring layers. The thermally conductive member is configured to circulate a heat transfer fluid therein. 
     Accordingly, in the transformer of the disclosure, the first thermally conductive member is disposed between the adjacent two wiring layers of the winding, so the heat produced by the winding during the operation of the transformer can be effectively dissipated. Therefore, the difference between the temperature of the transformer of the disclosure in operation and the room temperature can be significantly reduced, so as to improve the performance of the transformer of the disclosure. 
     It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the disclosure as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure can be more fully understood by reading the following detailed description of the embodiment, with reference made to the accompanying drawings as follows: 
         FIG. 1  is a perspective view of a transformer according to an embodiment of the disclosure; 
         FIG. 2  is a partial top view of the transformer in  FIG. 1 ; 
         FIG. 3  is an abridged general view of some components of the transformer in  FIG. 1 ; 
         FIG. 4  is a cross-sectional view of the first thermally conductive member taken along line  4 - 4  in  FIG. 3 ; and 
         FIG. 5  is an abridged general view of some components of a transformer according to another embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the present embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. 
     Reference is made to  FIGS. 1 and 2 .  FIG. 1  is a perspective view of a transformer  100  according to an embodiment of the disclosure.  FIG. 2  is a partial top view of the transformer  100  in  FIG. 1 . As shown in  FIGS. 1 and 2 , in the embodiment, the transformer  100  includes an iron core  110 , a plurality of windings  120 , a plurality of first thermally conductive members  130 , a plurality of second thermally conductive members  140 , and a fluid output module  150 . The iron core  110  includes a plurality of core portions  111 . The windings  120  are respectively wound onto the core portions  111 . The first thermally conductive members  130  are respectively corresponded to the core portions  111 , and the second thermally conductive members  140  are also respectively corresponded to the core portions  111 . Each of the windings  120  has a plurality of wiring layers  121 . Each of the first thermally conductive members  130  is thermally connected between adjacent two of the wiring layers  121  of the corresponding winding  120 . Hence, the wiring layers  121  thermally connected to the first thermally conductive member  130  can transfer the produced heat to the first thermally conductive member  130 . Each of the second thermally conductive members  140  is thermally connected between the corresponding core portion  111  and the corresponding winding  120 . Hence, the core portion  111  and the winding  120  thermally connected to the second thermally conductive members  140  can transfer the produced heat to the second thermally conductive members  140 . The first thermally conductive members  130  and the second thermally conductive members  140  are in fluid communication with each other and configured to circulate a heat transfer fluid L (see to  FIG. 4 ) therein. The fluid output module  150  is configured to provide the heat transfer fluid L to the second thermally conductive members  140 , so the heat transfer fluid L flows to the first thermally conductive members  130  through the second thermally conductive members  140 . 
     With the foregoing structural configurations, the heat that the second thermally conductive members  140  absorb from the thermally connected core portions  111  and the windings  120  can be transferred away by the heat transfer fluid L flowing in the second thermally conductive members  140 , and the heat that the first thermally conductive members  130  absorb from the thermally connected wiring layers  121  can be transferred away by the heat transfer fluid L flowing in the first thermally conductive members  130 , so as to significantly reduce the temperature of the whole transformer  100 . 
     In the embodiment, the transformer  100  further includes a fluid recycling module  160 . The fluid recycling module  160  is in fluid communication with the first thermally conductive members  130  and configured to recycle the heat transfer fluid L flowing in the first thermally conductive members  130 . In some embodiments, the fluid output module  150  and the fluid recycling module  160  can be further included in a fluid circulation device (not shown). The fluid circulation device is configured to cool (e.g., by using the cooling mechanism provided by a cooling module including components such as a compressor, a condenser, refrigerant, and etc.) the high temperature heat transfer fluid L recycled by the fluid recycling module  160  and circulate the cooled heat transfer fluid L to the second thermally conductive members  140  through the fluid output module  150 . 
     Reference is made to  FIG. 3 .  FIG. 3  is an abridged general view of some components of the transformer  100  in  FIG. 1 .  FIG. 3  illustrates a fluid path constituted by the first thermally conductive members  130  and the second thermally conductive members  140  disposed at one side of the iron core  110 . In the embodiment, the second thermally conductive members  140  are sequentially in fluid communication from a first end E 1  (i.e., the end proximal to the fluid output module  150 ) to a second end (i.e., the end distal to the fluid output module  150 ) of an arrangement direction A along which the core portions  111  are arranged. The first thermally conductive members  130  are sequentially in fluid communication from the first end E 1  to the second end E 2 . The first thermally conductive member  130  and the second thermally conductive member  140  that are arranged close to the second end E 2  the most are directly in fluid communication. The fluid output module  150  is configured to provide the heat transfer fluid L to the second thermally conductive member  140  that is arranged close to the second end E 2  the most. The fluid recycling module  160  is configured to recycle the heat transfer fluid L from the first thermally conductive member  130  that is arranged close to the first end E 1  the most. In other words, the heat transfer fluid L provided by the fluid output module  150  sequentially flows from the second thermally conductive member  140  arranged close to the first end E 1  the most to the second thermally conductive member  140  arranged close to the second end E 2  the most, then sequentially flows from the first thermally conductive member  130  arranged close to the second end E 2  the most to the first thermally conductive member  130  arranged close to the first end E 1  the most, and finally is recycled by the fluid recycling module  160 . 
     In the embodiment, a fluid inlet and a fluid outlet of each of the first thermally conductive members  130  and the second thermally conductive members  140  are respectively located at the upper side and the lower side, but the disclosure is not limited in this regard. In the embodiment, the fluid inlet and the fluid outlet of at least one of the first thermally conductive members  130  and the second thermally conductive members  140  are located at the same side (i.e., the upper side or the lower side). 
     In practical applications, with reference to  FIG. 1 , the fluid paths constituted by the first thermally conductive members  130  and the second thermally conductive members  140  disposed at two sides of the iron core  110  can be selectively designed to be symmetric or asymmetric. That is, the fluid paths at two sides of the iron core  110  can be flexibly adjusted as needed. For example, the heat transfer fluids L in both of the fluid paths flowing from the first end E 1  may cause the temperatures of the core portion  111  and the winding  120  arranged at the second end E 2  to be greater than the temperatures of the core portion  111  and the winding  120  arranged at the first end E 1 , which may result in the uneven heat dissipation of the transformer  100  and affect the overall performance. In order to eliminate the temperature difference between the first end E 1  and the second end E 2 , the heat transfer fluid L in the fluid path located at one side of the iron core  110  can flow from the first end E 1 , and the heat transfer fluid L in the fluid path located at another side of the iron core  110  can flow from the second end E 2 . 
     In some embodiments, the first thermally conductive members  130  and the second thermally conductive members  140  are structurally the same. Reference is made to  FIG. 4 .  FIG. 4  is a cross-sectional view of the first thermally conductive member  130  taken along line  4 - 4  in  FIG. 3 . As shown in  FIG. 4  taking the first thermally conductive member  130  as an illustration, the first thermally conductive member  130  is a metal board having a flow channel  131  therein, and the heat transfer fluid L flows in the flow channel  131 . In some embodiments, the first thermally conductive member  130  can be assembled by two plates, but the disclosure is not limited in this regard. In some embodiments, the flow channel  131  is formed in the interior of the first thermally conductive member  130  in a repetitive circuitous form similar to the S-shape, but the disclosure is not limited in this regard. 
     Reference is made to  FIG. 5 .  FIG. 5  is an abridged general view of some components of a transformer  100  according to another embodiment of the disclosure.  FIG. 5  illustrates a fluid path constituted by the first thermally conductive members  130  and the second thermally conductive members  140  disposed at one side of the iron core  110 . In the embodiment, the second thermally conductive members  140  are individually in fluid communication with the fluid output module  150 . The first thermally conductive members  130  are individually in fluid communication with the fluid recycling module  160 . The second thermally conductive members  140  are respectively in fluid communication with the first thermally conductive members  130 . In other words, the fluid output module  150  provides the heat transfer fluid L to the second thermally conductive members  140  at the same time, the heat transfer fluid L flowing in each of the second thermally conductive members  140  then flows to the corresponding one of the first thermally conductive members  130 , and the fluid recycling module  160  recycles the heat transfer fluid L from the first thermally conductive members  130  at the same time. With the fluid path of the present embodiment, the temperatures of the core portion  111  and the winding  120  arranged at the second end E 2  can be more consistent with the temperatures of the core portion  111  and the winding  120  arranged at the first end E 1 , and the heat produced by the transformer  100  can be uniformly dissipated. 
     In some embodiments, the transformer  100  can be designed to provide the heat transfer fluid L to the first thermally conductive members  130  by the fluid output module  150  and recycle the heat transfer fluid L from the second thermally conductive members  140  by the fluid recycling module  160 . For example, if the iron core  110  produces more heat than the windings  120  (or the iron core  110  has a higher temperature), the heat transfer fluid L can be provided to the second thermally conductive members  140  by the fluid output module  150 , so as to rapidly take the heat produced by the iron core  110  away by the heat transfer fluid L having a lower temperature and avoid a lot of heat accumulated in the iron core  110 . Relatively, if the windings  120  produce more heat than the iron core  110  (or the windings  120  have higher temperatures), the heat transfer fluid L can be provided to the first thermally conductive members  130  by the fluid output module  150 , so as to rapidly take the heat produced by the windings  120  away by the heat transfer fluid L having a lower temperature and avoid a lot of heat accumulated in the windings  120 . 
     As shown in  FIGS. 1 and 2 , in the embodiment, the transformer  100  further includes a plurality of ventilation strips  170 . Each of the ventilation strips  170  is disposed between adjacent two of the wiring layers  121  and configured to maintain a gap between the adjacent two of the wiring layers  121 . Hence, it is helpful for the external airflow to pass through the gap to take the heat produced by the wiring layers  121  away. 
     In the embodiment, any adjacent two of the wiring layers  121  between which no first thermally conductive member  130  is disposed are disposed with the ventilation strips  170 . That is, for any adjacent two of the wiring layers  121  between which at least one first thermally conductive member  130  is disposed, the heat produced by the wiring layers  121  can be taken away by the first thermally conductive member  130  in a heat conduction manner; and for any adjacent two of the wiring layers  121  between which no first thermally conductive member  130  is disposed, the heat produced by the wiring layers  121  can be taken away via the gap formed by the ventilation strips  170  in a heat convection manner. 
     As shown in  FIGS. 1 and 2 , in the embodiment, the transformer  100  further includes a plurality of insulating layers  180  respectively disposed between the wiring layers  121  and between the iron core  110  and each of the windings  120 , and configured to insulate the wiring layers  121  from each other and insulate the iron core  110  from each of the windings  120 . In some embodiments, the insulating layers  180  are insulating papers, but the disclosure is not limited in this regard. 
     In some embodiments, the transformer  100  can only include the first thermally conductive members  130  without the second thermally conductive members  140 , the fluid output module  150  directly provides the heat transfer fluid L to the first thermally conductive members  130 , and the fluid recycling module  160  directly recycle the heat transfer fluid L from the first thermally conductive members  130 . In some other embodiments, the transformer  100  can only include the second thermally conductive members  140  without the first thermally conductive members  130 , the fluid output module  150  directly provides the heat transfer fluid L to the second thermally conductive members  140 , and the fluid recycling module  160  directly recycle the heat transfer fluid L from the second thermally conductive members  140 . 
     As shown in  FIG. 1 , in the embodiment, the number of the core portions  111  included by the iron core  110  and the numbers of the first thermally conductive members  130  and the second thermally conductive members  140  at one side of the iron core  110  are three, but the disclosure is not limited in this regard and can be flexibly adjusted as needed. In practical applications, the type of the iron core  110  adopted in the transformer  100  is not limited by the iron core  110  shown in  FIG. 1 . 
     As shown in  FIG. 1 , in the embodiment, the number of the wiring layers  121  included in each of the windings  120  is four, but the disclosure is not limited in this regard and can be flexibly adjusted as needed. 
     In some embodiments, the material of the wiring layers  121  includes copper, but the disclosure is not limited in this regard. 
     According to the foregoing recitations of the embodiments of the disclosure, it can be seen that in the transformer of the disclosure, the first thermally conductive member is disposed between the adjacent two wiring layers of the winding, so the heat produced by the winding during the operation of the transformer can be effectively dissipated. Therefore, the difference between the temperature of the transformer in operation and the room temperature can be significantly reduced, so as to improve the performance of the transformer of the disclosure. In order to decrease the temperature of the transformer more efficiently, the transformer of the disclosure further includes the second thermally conductive member disposed between the iron core and the winding, so as to so the heat produced by the iron core during the operation of the transformer can be effectively dissipated. In addition, the transformer of the disclosure can selectively provide the heat transfer fluid from the first thermally conductive member or the second thermally conductive member according to the amounts of heat (or temperatures) of the iron core and the winding. 
     Although the present disclosure has been described in considerable detail with reference to certain embodiments thereof, other embodiments are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the embodiments contained herein. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present disclosure without departing from the scope or spirit of the disclosure. In view of the foregoing, it is intended that the present disclosure cover modifications and variations of this disclosure provided they fall within the scope of the following claims.