Parallel Secondary Winding Layout for Lower-Loss Transformers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional transformers experience increased winding loss and core loss due to the proximity effect and parasitic capacitance, which are not effectively mitigated by the alternate stacking of primary and secondary winding layers.
Innovation Solution
The transformer design includes a primary winding and two secondary windings with winding layers stacked along the axial direction, where the secondary winding layers are electrically connected in parallel, and the distance between windings is optimized to reduce parasitic capacitance and proximity effects, with thicker conductors in secondary windings for improved heat dissipation and reduced skin effect resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If winding layers are alternately stacked to reduce size, then device compactness is improved, but proximity effect increases causing higher winding loss
Solution Approach 1:
The secondary winding is segmented into multiple secondary winding layers stacked in the axial direction, with each layer electrically connected in parallel. This segmentation allows increasing the distance between primary and secondary windings while maintaining compact overall structure, thereby reducing proximity effect and winding loss.
Solution Approach 2:
The patent transitions from radial stacking to axial stacking of winding layers. By arranging secondary winding layers along the axial direction of the core rather than radially, the distance between primary and secondary windings is increased, reducing magnetic coupling and proximity effect while maintaining transformer compactness.
2Volume of moving object
If winding layers are alternately stacked to reduce size, then device compactness is improved, but parasitic capacitance increases causing higher core loss
Solution Approach 1:
The secondary winding is divided into multiple secondary winding layers stacked axially, increasing the physical distance between primary and secondary windings. This segmentation reduces parasitic capacitance between windings, thereby reducing capacitive current and associated core losses.
Solution Approach 2:
Insulating layers are introduced as intermediaries between primary and secondary winding layers. These insulating layers increase the distance between windings and reduce parasitic capacitance, thereby reducing core loss while maintaining compact transformer structure.
3Loss of energy
If conductor thickness is increased to reduce skin effect, then AC resistance is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The secondary winding is segmented into multiple parallel-connected winding layers, each with optimized conductor thickness. This segmentation allows using thicker conductors in each layer (reducing skin effect and AC resistance) while maintaining overall heat dissipation capability through the parallel configuration and increased surface area.
Solution Approach 2:
Multiple secondary winding layers are electrically connected in parallel, combining their current-carrying capabilities. This merging allows each layer to use thicker conductors for reduced AC resistance while the parallel configuration maintains overall heat dissipation efficiency.
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 reduces total losses by minimizing parasitic capacitance-induced core loss and winding loss, while enhancing heat dissipation and AC resistance performance.
Implementation Method 1
a transformer including a core and a primary winding, a first secondary winding, and a second secondary winding wound around the core
Implementation Method 2
parasitic capacitance-induced core loss
Implementation Method 3
increased winding loss and core loss due to the proximity effect
Data Source
AI summary
A transformer includes a core and a primary winding, a first secondary winding, and a second secondary winding wound around the core. The first secondary winding includes first winding layers stacked along an axial direction of the core. The second secondary winding includes second winding layers stacked along the axial direction. The first winding layers are electrically connected in parallel to each other. The second winding layers are electrically connected in parallel to each other. A distance between the primary winding and the first secondary winding and a distance between the primary winding and the second secondary winding are greater than a distance between adjacent two of the first winding layers and a distance between adjacent two of the second winding layers.