Foil Winding Pulse Transformer With Uncut Core
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Solution Overview
Problem
Conventional pulse transformer designs require cutting the core into halves, leading to increased manufacturing costs, risk of electrical shorts, and excessive losses due to high frequency AC resistance, as well as higher DC reset current requirements.
Innovation Solution
A pulse transformer design utilizing an uncut core with multi-strip foil windings arranged around the core, eliminating the need for core cutting and allowing for easy insertion and connection of multiple independent primary windings, reducing the risk of shorts and losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core is cut into halves to allow winding insertion, then the windings can be practically applied, but manufacturing costs increase, risk of electrical shorts increases, and losses increase due to high frequency AC resistance
Solution Approach 1:
Instead of cutting the core to facilitate winding insertion, the patent inverts the approach by making the windings removable. The foil windings are designed to be inserted into an uncut core and can be easily removed and reinserted, eliminating the need for core cutting while maintaining practical manufacturability.
Solution Approach 2:
The patent changes the physical state and properties of the windings by using flexible foil material that can be deformed and inserted into the core. This parameter change in the winding material properties enables insertion into an uncut core, avoiding the harmful effects of core cutting.
2Ease of manufacture
If the core is cut into halves, then windings can be inserted, but DC reset current increases
Solution Approach 1:
The patent inverts the conventional approach by keeping the core uncut and making the windings removable instead. This eliminates the gap in the core that would otherwise increase magnetic reluctance and require higher DC reset current to demagnetize the core.
Solution Approach 2:
The patent extracts the removable feature from the windings rather than from the core. The foil windings are designed to be easily removable and reinsertable, which allows practical application without creating a core gap that would increase DC reset current requirements.
3Ease of manufacture
If the core is cut into halves, then windings can be applied, but manufacturing costs increase
Solution Approach 1:
The patent inverts the complexity by eliminating core cutting operations. Instead of cutting and reconnecting the core, the design allows easy insertion and removal of foil windings into an uncut core, significantly simplifying the manufacturing process.
Solution Approach 2:
The patent segments the winding structure into multiple flexible foil strips that can be independently inserted and removed. This segmentation of the windings (not the core) enables practical application while avoiding the complexity of core cutting and reconnection.
4Ease of manufacture
If the core is cut into halves, then windings can be inserted, but the risk of electrical shorts increases
Solution Approach 1:
The patent inverts the approach by making windings removable rather than cutting the core. This eliminates the creation of sharp edges and exposed conductive surfaces on the core that would otherwise increase the risk of electrical shorts between windings and core.
Solution Approach 2:
The patent extracts the removable feature from the windings to enable insertion into an uncut core. This approach maintains the integrity of the core structure, eliminating the source of potential electrical shorts that would arise from core cutting and surface exposure.
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
The design reduces manufacturing costs, decreases DC reset current, minimizes electrical shorts, and avoids excessive losses by eliminating the need for core cutting and minimizing high frequency AC resistance, while providing a cost-effective and efficient pulse transformer arrangement.
Implementation Method 1
The pulse transformer is used for transferring pulse energy from the primary side to the secondary side, normally with a change in voltage and current. The transformer core is made of some magnetic material, and the windings are generally made of copper wires.
Implementation Method 2
The transformer core is made of some magnetic material, and the windings are generally made of copper wires. In operation, the transformer is often placed in a pulse transformer tank, where a suitable fluid such as oil can cool the components efficiently and provide electrical insulation.
Data Source
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AI summary
A pulse transformer arrangement (100) is built from an uncut pulse transformer core (110) and at least one foil winding (120-A, 120-B) (each) comprising multiple insulated conducting strips arranged around the core and ending in foil winding terminals to form multiple independent primary windings. This new design principle has several advantages. Making the winding(s) of foil eliminates the need to cut the core, because of the ease of insertion of the foil winding(s) onto the core. The work to set up a plurality of primary windings is significantly reduced. In addition to the elimination of the costs for cutting the core, this also brings the further advantages of reduced DC reset current, reduced risk for electrical shorts and avoidance of excessive losses due to potential high frequency AC resistance problems.