High Voltage Transformer Interleaved Winding Leakage Inductance
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Solution Overview
Problem
High-voltage, high-current transformers face challenges in compact designs due to high costs and susceptibility to failures, with existing solutions struggling to minimize inductive losses and prevent breakdowns while maintaining efficiency.
Innovation Solution
The design incorporates a closed loop core with multiple primary and secondary windings arranged on separate legs, utilizing interleaved winding sections and fractional turns to reduce leakage inductance and electromagnetic interference, and employing enclosures to manage current flow directions and minimize losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltage and high current are used in the transformer, then power output is improved, but inductive losses and electromagnetic interference increase
Solution Approach 1:
The transformer windings are segmented into multiple sections arranged in an interleaved pattern. Primary and secondary windings are divided into multiple segments that alternate positions around the core legs, reducing the overall leakage inductance of each winding section while maintaining high power output capability
Solution Approach 2:
The patent transitions from traditional planar winding arrangements to a three-dimensional interleaved configuration around core legs. Windings are positioned at different angular positions and radial distances, creating a multi-dimensional spatial arrangement that reduces electromagnetic interference and inductive losses while preserving high power transmission
2Object-affected harmful factors
If shielding is added to reduce electromagnetic fields and parasitic currents, then electromagnetic interference is reduced, but device complexity and cost increase
Solution Approach 1:
The patent converts the potentially harmful electromagnetic fields generated by high voltage/current operation into beneficial effects by using the magnetic flux from primary windings to directly induce voltage in secondary windings through controlled magnetic coupling. The interleaved arrangement ensures that electromagnetic energy is channeled productively rather than being suppressed as interference
Solution Approach 2:
The magnetic core acts as an intermediary that mediates energy transfer between primary and secondary windings. By providing a controlled magnetic path through the core, the system achieves efficient energy transfer without requiring additional shielding, as the magnetic coupling is confined and directed through the core structure
3Volume of moving object
If compact design is implemented to reduce transformer size, then volume is reduced, but manufacturing difficulty and susceptibility to failures increase
Solution Approach 1:
The transformer is segmented into modular units with standardized winding sections that can be manufactured separately and assembled around core legs. This modular segmentation enables compact overall dimensions while maintaining manufacturability through repeated use of standardized components
Solution Approach 2:
Multiple winding sections are nested concentrically around the same core legs in an interleaved pattern. Primary and secondary windings are positioned at different radial distances and angular positions, creating a nested configuration that maximizes space utilization and achieves compact dimensions without compromising manufacturing feasibility
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 achieves low inductive losses, prevents corona breakdowns, and reduces electromagnetic interference, enabling long-term corona-free operation and improved efficiency in high-frequency transformer applications.
Implementation Method 1
An alternating current provided at the input (e.g., primary) windings causes a varying magnetic flux in the transformer core. This flux leads to a time varying magnetic field that includes a voltage in the output (e.g., secondary) windings of the transformer.
Implementation Method 2
The design incorporates a closed loop core with multiple primary and secondary windings arranged on separate legs, utilizing interleaved winding sections and fractional turns to reduce leakage inductance and electromagnetic interference
Implementation Method 3
This configuration achieves low inductive losses, prevents corona breakdowns, and reduces electromagnetic interference, enabling long-term corona-free operation
Data Source
AI summary
A transformer includes a closed loop core having a first leg and a second leg. The transformer also includes a first primary winding surrounding the first and second legs, a second primary winding surrounding the first and second legs, and first and second secondary windings surrounding the first and second legs, respectively, and disposed between the first and second primary windings. A first turn of the first and second secondary windings are disposed on a first interlayer winding layer, and other turns of the first and second secondary windings are disposed on a first layer that is further from the first primary winding than the first interlayer winding layer.