Multilayer Spiral Transformer Core Penetration
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Solution Overview
Problem
Conventional transformers experience reduced coupling between windings due to gaps caused by the conventional single-layer spiral winding method, leading to lower current density and efficiency under high current requirements.
Innovation Solution
A transformer design featuring a multilayer spiral coil with through holes and a core that penetrates these holes, allowing both ends of the conductive wire to extend outward from the periphery, enhancing coupling and current density by eliminating gaps between windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer spiral wire cake is used with conventional winding method, then the manufacturing process is simple, but gaps exist between wire cakes reducing coupling between windings
Solution Approach 1:
The patent transitions from a single-layer spiral winding to a multilayer spiral coil structure. The conductive wire is wound in multiple layers around the bobbin, with each layer positioned radially outward from the previous layer. This dimensional change eliminates gaps between wire cakes and improves coupling between windings while maintaining manufacturing simplicity through the same basic winding process.
2Power
If the number of turns of the coil is increased to meet high current requirements, then the current capacity is improved, but the beginning end of the wire has to turn outward creating gaps that reduce coupling
Solution Approach 1:
The patent implements a nested multilayer spiral coil structure where multiple turns of the conductive wire are wound concentrically around the bobbin. Each layer is nested within the radial space of the outer layers, allowing increased number of turns for higher current capacity without creating gaps. The nested arrangement ensures tight coupling between all windings while accommodating the required number of turns.
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 achieves a higher extent of coupling between windings and increased current density, thereby enhancing the efficiency of the transformer.
Implementation Method 1
The second electrical conductor includes at least one multilayer spiral coil, which is formed by winding a conductive wire and has a through hole at its central portion. Both ends of the conductive wire extend outward from a periphery of the multilayer spiral coil. The core penetrates through the through hole and covers at least one portion of the first electrical conductor and the second electrical conductor.
Data Source
AI summary
A transformer includes a first electrical conductor, a second electrical conductor and a core. The second electrical conductor is electromagnetically coupled with the first electrical conductor. The second electrical conductor includes at least one multilayer spiral coil, which is formed by winding a conductive wire and has a through hole at its central portion. Both ends of the conductive wire extend outward from a periphery of the multilayer spiral coil. The core penetrates through the through hole and covers at least one portion of the first electrical conductor and the second electrical conductor.