Nested Flat-Wound Transformer Coils for Higher Fill Factor
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Solution Overview
Problem
Existing transformers and inductors have limited conductor fill factor, lack design flexibility, and are restricted in varying thickness and number of wires, limiting their ability to achieve higher power with reduced height and size.
Innovation Solution
The use of nested flat wound coils with inner and outer windings, allowing for variable thickness and arrangement, enabling higher turn counts and multiple rows of windings, and utilizing flat or edge-wound magnet wire to create windings that can be stacked and nested, with connections to pins for efficient electrical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If printed circuit boards are used for windings, then manufacturing is simplified, but conductor fill factor is limited to approximately 35%
Solution Approach 1:
The winding structure is segmented into multiple independent flat windings that can be nested within each other. Each winding is a separate component that can be manufactured and then assembled in a nested configuration, allowing for higher conductor density while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
Multiple flat windings are nested within each other in a concentric arrangement, similar to nested dolls. This nesting approach maximizes the use of available space within the transformer window, significantly increasing the conductor fill factor from 35% to potentially 60-70% while keeping the overall device size compact.
2Device complexity
If traditional windings are used, then structure is simple, but design flexibility for varying thickness and number of wires is limited
Solution Approach 1:
The winding design allows for dynamic variation in the number of flat windings, their thicknesses, and dimensions. Designers can selectively add or remove windings and adjust their parameters to meet different electrical requirements, providing flexibility without significantly increasing structural complexity since each winding follows the same basic flat construction pattern.
3Power
If higher power transformers are designed, then power capacity increases, but device height increases
Solution Approach 1:
The transformer design transitions from a vertical stacking arrangement to a horizontal nested arrangement. By nesting windings concentrically in the horizontal plane rather than stacking them vertically, the design achieves higher power capacity through increased conductor fill factor while maintaining a compact vertical profile, thus reducing device height.
4Power
If more windings are added to increase power, then power capacity increases, but device size increases
Solution Approach 1:
Multiple windings are nested concentrically within each other, allowing many windings to be packed into a compact volume. This nesting approach enables the addition of more windings to increase power capacity without proportionally increasing device size, as the windings occupy overlapping spatial regions rather than requiring additional linear space.
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 allows for higher power transformers with reduced height, improved conductor fill factor, and increased design flexibility, supporting higher voltages and currents while minimizing leakage inductance and resistive losses.
Implementation Method 1
a varying current in the transformer's primary winding creates a varying magnetic flux in the transformer core and a varying magnetic field impinging on the transformer's secondary winding. This varying magnetic field at the secondary winding induces a varying EMF or voltage in the secondary winding due to electromagnetic induction
Implementation Method 2
Transformers rely on Faraday's Law and high magnetic permeability core properties, to efficiently change AC voltages from one voltage level to another
Data Source
AI summary
An electro-magnetic device is provided, including a first winding set of nested windings, and a second winding set of nested windings positioned adjacent to the first winding set. A method of making an electro-magnetic device including a first winding set of nested windings, and a second winding set of nested windings positioned adjacent to the first winding set is also provided.