Isolation Transformer Layout for Stronger Coupling and Isolation
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Solution Overview
Problem
Potted isolation transformers face issues with defects in materials leading to transformer failures due to de-bonding or de-lamination, and exhibit poor magnetic coupling and high inductance leakage due to physical separation of primary and secondary windings, which are undesirable in certain applications.
Innovation Solution
An isolation transformer is designed without potting or encapsulation materials, using primary and secondary side wires with different insulation thicknesses and a plurality of magnetic cores to provide voltage isolation, allowing for closer proximity of the wires and improved magnetic coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting or encapsulation materials are used in isolation transformers, then voltage isolation is achieved, but material defects cause transformer failures due to de-bonding or de-lamination
Solution Approach 1:
The patent removes potting or encapsulation materials from the transformer construction, eliminating the source of de-bonding and de-lamination failures. The isolation transformer achieves voltage isolation through the inherent insulation properties of the primary and secondary windings and their physical arrangement, without requiring additional potting compounds that can defect and fail.
2Reliability
If primary and secondary windings are physically separated, then voltage isolation is provided, but magnetic coupling deteriorates and inductance leakage increases
Solution Approach 1:
The patent applies different insulation thicknesses to the primary and secondary windings, with the first winding having a first insulation thickness and the second winding having a second insulation thickness. This local differentiation allows optimal balance between voltage isolation (achieved through sufficient insulation at critical points) and magnetic coupling (maintained through closer overall proximity of windings), eliminating the need for excessive physical separation.
3Reliability
If different insulation thicknesses are used for primary and secondary wires, then voltage isolation is optimized, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies particular insulation thickness ranges for the primary and secondary windings (first insulation thickness and second insulation thickness respectively), optimizing the balance between voltage isolation capability and manufacturing feasibility. This parameter optimization ensures adequate isolation without requiring excessively tight tolerances that would make manufacturing impractical.
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 solution achieves similar voltage isolation to potted transformers without the need for potting materials, simplifying construction and reducing engineering hours, while providing stronger magnetic coupling and lower inductance leakage.
Implementation Method 1
a plurality of magnetic cores of magnetic material that can be configured to surround portions of each of the first and second wires along respective circumferences of the first and second wires to provide the isolation transformer
Implementation Method 2
The isolation transformer can further include a primary side wire having a first insulation thickness that can define a voltage isolation level for the isolation transformer from a primary electrical source or a load and a secondary side wire having a second insulation thickness that can define a voltage isolation level of the isolation transformer from a secondary electrical source or the load
Data Source
AI summary
In some examples, an isolation transformer can include a first wire having a first insulation thickness and a second wire having a second insulation thickness that is different than the first insulation thickness. The isolation transformer can further include a plurality of magnetic cores of magnetic material that can be configured to surround portions of each of the first and second wires along respective circumferences of the first and second wires to provide the isolation transformer.