Client: C&D Technologies

Project Objectives:
Reduce transformer winding temperatures by 20% in the battery charger, without using fans or changing the form factor of the system.

Achievements:
Due to the geometry of the transformer, direct heat sinking of the winding was difficult. Instead, using simulations, side panels were designed to enhance radiation and natural convection, bringing the windings within their temperature specifications. Applied Thermal simulations were validated by C&D to be within 4% of actual prototype temperatures.

Client: Calpine

Project Objectives:
Using forced air convection, cool several banks of IGBTs in a minimal volume.

Achievements:
This was one of Applied Thermal’s first projects to marry simulation and prototype testing, rapidly converging to an optimal thermal design. A high-aspect ratio, bonded-fin heat sink was shown to provide the best performance in the minimal volume. Placement of the fans and banks of IGBTs on the heat sink were optimized. Furthermore, an intermediate heat spreader was shown to reduce temperatures an additional 20% by enlarging the surface area available for attachment to the heat sink base.

• Valere Power
• Artesyn
• many others