High-Voltage Transformer Winding Layout for Low Stray Capacitance
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Solution Overview
Problem
Existing high-voltage transformer designs face challenges in achieving high voltage outputs with fast rise times and low stray inductance and capacitance, which are essential for applications such as fusion science, medical devices, and semiconductor manufacturing, while also minimizing corona discharge and energy loss.
Innovation Solution
A high-voltage transformer design featuring a transformer core with a single-turn primary winding and a multi-turn secondary winding, where the secondary windings are spaced further apart from the core to reduce stray inductance and capacitance, and the transformer core is constructed with materials like ferrite or air to minimize energy loss and corona discharge, achieving voltage outputs greater than 1200 volts with rise times less than 150 nanoseconds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the secondary windings are placed close to the transformer core to increase coupling and reduce inductance, then the magnetic coupling is improved, but the stray capacitance increases and corona discharge is more likely to occur
Solution Approach 1:
The patent applies local quality by varying the spacing of secondary windings from the core along the axial direction. Windings at different positions have different distances from the core, creating localized variations in coupling strength and capacitance. This allows optimal coupling in some regions while minimizing capacitance and corona discharge in others, resolving the contradiction between magnetic coupling strength and stray capacitance reduction.
2Power
If the transformer core uses high permeability material to reduce inductance, then the magnetic efficiency is improved, but the energy loss increases due to hysteresis and eddy currents
Solution Approach 1:
The patent employs composite material strategy by combining ferrite material with air gaps in the transformer core structure. The ferrite provides high magnetic permeability for efficient magnetic coupling, while the air gaps interrupt the magnetic path to reduce eddy current loops and hysteresis losses. This composite approach allows the system to achieve both high magnetic efficiency and low energy loss simultaneously.
3Speed
If the transformer is designed for high voltage output with fast rise time, then the pulse performance is improved, but the stray inductance and capacitance must be minimized which complicates the design
Solution Approach 1:
The patent applies segmentation by dividing the secondary winding into multiple sections with different spacing from the core along the axial direction. This segmented structure allows different portions of the winding to serve different functions: some sections provide strong coupling for voltage transformation while others are spaced further to reduce capacitance and inductance. This segmentation enables achievement of fast rise time high voltage output without excessive design complexity.
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 effectively produces high voltage outputs with fast rise times and low stray inductance and capacitance, reducing energy loss and the likelihood of corona discharge, making it suitable for demanding applications.
Implementation Method 1
A high-voltage transformer includes a transformer core; at least one primary winding wound once or less than once around the transformer core; and a secondary winding wound around the transformer core a plurality of times
Data Source
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AI summary
A high-voltage transformer is disclosed. The high-voltage transformer includes a transformer core; at least one primary winding wound once or less than once around the transformer core; a secondary winding wound around the transformer core a plurality of times; an input electrically coupled with the primary windings; and an output electrically coupled with the secondary windings that provides a voltage greater than 1,1200 volts. In some embodiments, the high-voltage transformer has a stray inductance of less than 30 nH as measured on the primary side and the transformer has a stray capacitance of less than 100 pF as measured on the secondary side .