Jointless Transformer Windings via Single Loop Folding
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Solution Overview
Problem
Transformer windings with solder joints experience higher electrical resistivity, leading to increased power loss and manufacturing complexity and cost.
Innovation Solution
Designing windings configured from a single loop of electrically conductive material, eliminating solder joints and using folding techniques to form turns, which reduces electrical resistivity and simplifies manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple strips of electrically conductive material are folded and soldered together to form windings, then the winding structure can be assembled, but solder joints are created that increase electrical resistivity and power loss
Solution Approach 1:
The patent merges multiple separate conductive strips into a single continuous loop of electrically conductive material. This single loop is then folded and formed to create the winding structure, eliminating the need for solder joints between multiple strips. The merging of materials directly reduces electrical resistivity and power loss while simplifying the overall structure.
Solution Approach 2:
The patent extracts and eliminates the solder joints from the winding structure by using a single continuous loop of conductive material. By removing the solder joints that connect multiple strips, the invention eliminates the source of increased electrical resistivity and power loss, while also simplifying the manufacturing process.
2Ease of manufacture
If multiple strips are soldered together to form windings, then the winding can be constructed, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple separate manufacturing steps (cutting multiple strips, positioning them, soldering joints) into a single process of forming and folding one continuous loop. This merging of manufacturing operations dramatically simplifies the production process, reduces labor requirements, and lowers manufacturing costs while eliminating structural complexity.
Solution Approach 2:
The patent removes the soldering operation entirely from the manufacturing process by using a single continuous loop of conductive material. This extraction of the soldering step eliminates the associated complexity, skill requirements, equipment needs, and quality control issues, thereby simplifying manufacturing and reducing costs.
3Reliability
If solder joints are used in windings, then multiple strips can be connected, but electrical resistivity increases at joint locations
Solution Approach 1:
The patent merges multiple separate conductive strips into one continuous loop, eliminating the interfaces between strips where solder joints would be required. This continuous material provides uniform electrical properties throughout the winding, ensuring reliable electrical connection while minimizing power loss through reduced resistivity.
Data Source
AI summary
A transformer includes at least two windings. Each winding has at least one turn, and the windings are configured from a loop of electrically conductive material.