Ceramic Insulated Transformer Segmentation for Clearance

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Solution Overview

Problem

Designing transformers with sufficient strike distance and creepage distance while maintaining a small form factor is challenging due to the difficulty in separating primary and secondary windings effectively within a compact structure.

Innovation Solution

A transformer design featuring a clamshell-type ceramic housing where the primary winding is enclosed within the housing and the secondary winding is disposed outside, with a core extending through apertures, allowing for sufficient strike and creepage distances while maintaining a small form factor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the primary and secondary windings are placed close together to reduce transformer size, then the form factor is reduced, but the strike distance and creepage distance become insufficient

Engineering Contradiction:

Improvetransformer sizeVSAvoidstrike distance and creepage distance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The housing is divided into a first portion and a second portion that are separated by a gap, with each portion containing different windings. This segmentation physically isolates the primary and secondary windings while maintaining a compact overall structure, resolving the contradiction between small size and sufficient clearance distances.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A ceramic housing is introduced as an intermediary material between the primary and secondary windings. The ceramic material provides excellent electrical insulation properties, ensuring sufficient strike distance and creepage distance while allowing the windings to be positioned close together for compact dimensions.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the primary and secondary windings are separated to increase strike distance and creepage distance, then electrical insulation is improved, but the transformer form factor increases

Engineering Contradiction:

Improvestrike distance and creepage distanceVSAvoidtransformer size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A ceramic housing is used to enclose the windings, utilizing the composite structure of ceramic material to provide both mechanical support and electrical insulation. The ceramic material's high dielectric strength allows for compact design while maintaining adequate strike and creepage distances.

Inventive Principle:

Principle #40Composite materials

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

This configuration effectively achieves sufficient strike and creepage distances without increasing the transformer's size, ensuring reliable operation and preventing electrical shorts.

Implementation Method 1

a core extending through a first aperture in the housing

Methodology Applied

Scientific EffectMagnetic flux: Magnetic Field

Implementation Method 2

Based on a ratio of the number of turns in the primary winding to the number of turns in the secondary winding, the transformer may increase or decrease the voltage output

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

it may be difficult to achieve sufficient strike distance (the shortest distance between two conductors through air) and creepage distance (the shortest distance between two conductors along a surface of an insulator)

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS10262784B2Ceramic insulated transformer

Publication Date: 2019.04.16 GE INFRASTRUCTURE TECH LLC

AI summary

A transformer includes a ceramic housing, a primary winding disposed within the housing, a secondary winding disposed outside the winding, and a core extending through a first aperture in the housing. The housing includes a first portion and a second portion. Each of the first and second portions include a planar structure having a first housing aperture, and a plurality of sidewalls extending perpendicular to the planar structure along a plurality of edges of the planar structure. The first and second portions interface with one another when the ceramic housing is assembled such that the sidewalls of the first and second portions overlap with one another.