Coreless High-Voltage Pulse Transformer for Compact Short-Pulse Output
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional high-voltage pulse transformers are bulky, heavy, and inefficient due to their large size and inductive coupling issues, making them unsuitable for compact portable devices like electroshock weapons, and they struggle to achieve high transformation ratios and short pulses.
Innovation Solution
A small-sized high-voltage pulse transformer design without a magnetic core, where the secondary winding is wound directly on a conductive or non-conductive support element with minimal bending radius, using interlayer and interwinding insulation, and filled with electrical insulating material to maximize coupling and reduce magnetic induction dissipation fluxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a traditional high-voltage pulse transformer with a magnetic core and large winding diameter is used, then the transformer can provide high voltage output, but the device becomes bulky and heavy, occupying up to 1/3 of the total device volume
Solution Approach 1:
The patent removes the magnetic core from the transformer design, extracting the problematic component that caused bulkiness and weight. The coreless design eliminates the need for large winding diameters and complex framing structures, directly reducing transformer volume while maintaining high voltage output capability through optimized air-core winding geometry
Solution Approach 2:
The patent implements nested winding structures where the primary and secondary windings are positioned in concentric arrangements with minimal spacing. The windings are nested within a compact cylindrical structure filled with insulating material, maximizing space utilization and achieving high transformation ratios in a minimized volume
2Stability of the object's composition
If a traditional transformer with a magnetic core is used, then the transformer can provide stable voltage output, but the inductance increases, preventing the generation of short pulses required for nanosecond pulse technology
Solution Approach 1:
By removing the magnetic core, the patent eliminates the source of high inductance that prevented short pulse generation. The coreless design reduces inductance to acceptable levels while maintaining voltage stability through precise winding geometry and optimized interwinding insulation structures
Solution Approach 2:
The patent changes the fundamental parameter of inductance by transitioning from a magnetic core design to a coreless design. This parameter change enables short pulse generation while voltage stability is maintained through optimized winding arrangements and insulation configurations that ensure consistent electromagnetic coupling
3Reliability
If air insulation with several centimeters of air gap is used between primary and secondary windings, then the transformer can prevent electrical breakdown, but the inductive coupling becomes weak (not more than 0.1), reducing transformation efficiency
Solution Approach 1:
The patent replaces thick air insulation with thin-film interwinding insulation materials that provide high electrical strength in minimal thickness. These thin insulation layers maintain reliable electrical isolation between windings while allowing the windings to be positioned in close proximity, maximizing inductive coupling and transformation efficiency
Solution Approach 2:
The patent employs composite insulation structures combining multiple material layers with different properties. The interwinding insulation uses materials with high dielectric strength and low loss characteristics, creating a composite structure that simultaneously achieves reliable electrical insulation and high inductive coupling through optimized material selection and layer configuration
4Stress or pressure
If a large difference in diameter between primary and secondary windings (3-5 times) is used, then the transformer can accommodate more turns for high voltage output, but the device size increases significantly, making it unsuitable for portable applications
Solution Approach 1:
The patent implements nested concentric windings where the primary and secondary coils are arranged in tight cylindrical configurations with minimal radial spacing. This nesting approach allows achieving high transformation ratios through optimized turn counts and winding densities without requiring large diameter differences, keeping the transformer compact for portable applications
Solution Approach 2:
The patent changes the geometric parameters of the windings by optimizing the radius ratio and turn densities rather than relying on large diameter differences. Through precise control of winding parameters such as turn counts, wire diameters, and spacing, the patent achieves high voltage transformation in a compact geometry suitable for portable devices
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 design results in a compact, efficient, and cost-effective transformer with increased no-load voltage and transformation ratio, enabling the use in portable devices and achieving short pulses, as demonstrated by the creation of a full-fledged small-size contact remote-acting electroshock weapon.
Implementation Method 1
a primary winding (1), connected to a source of time-varying voltage and generating a time-varying magnetic field
Implementation Method 2
a secondary winding (2), wound on the support element and generating a voltage induced by the magnetic field generated by the primary winding
Data Source
AI summary
The invention relates to electrical engineering, technology for producing high voltages, portable devices for supplying a high voltage to ozonizers, ionizers, gas-discharge lamps and lasers, technology for producing nanosecond pulses, and primarily to output stage technology for electroshock devices. The technical result is reduced weight and dimensions, an improved manufacturing process and a reduced price. A high-voltage pulse transformer preferably comprises a secondary winding wound on a preferably removable support element, without a mandrel, frame, template or sleeve, in layers with insulation between said layers, and a primary winding separated from the secondary winding by insulation between the windings. The entire structure is potted with an electrical insulating compound or an electrical insulating liquid.