Segmented Transformer Coil Layout for Lower Proximity Loss
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Solution Overview
Problem
The proximity effect in transformer units causes current to concentrate near the primary and secondary coils, leading to increased energy loss, particularly in coils with fewer turns, as currents flow in a concentrated manner, resulting in higher current density and energy loss.
Innovation Solution
The transformer unit design includes a primary side coil with a metal plate winding body and a secondary side coil with multiple windings arranged on opposite sides of the metal plate winding body, reducing the proximity effect and distributing current density more evenly, thereby minimizing energy loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If current flows through the primary side coil and secondary side coil in a conventional transformer configuration, then voltage transformation is achieved, but current concentrates on portions close to each other due to proximity effect, leading to increased energy loss
Solution Approach 1:
The secondary side coil is divided into multiple windings (first winding and second winding) that are arranged on opposite sides of the metal plate winding body. This segmentation distributes the magnetic field interaction across multiple separated sections, reducing the concentration of current density in any single location and thereby mitigating the proximity effect.
Solution Approach 2:
The patent applies different winding structures to different locations: the metal plate winding body is positioned at the center while the first and second windings are positioned on opposite sides. This creates a non-uniform spatial distribution of windings that optimizes magnetic coupling while reducing localized current concentration and proximity effect in critical areas.
2Device complexity
If one of the coils has a smaller number of turns, then the coil structure is simpler, but a larger current flows through it, causing increased energy loss
Solution Approach 1:
The secondary side coil is segmented into multiple windings (first winding and second winding) that are arranged on opposite sides of the metal plate winding body. This segmentation distributes the magnetic field interaction across multiple separated sections, reducing the concentration of current density in any single location and thereby mitigating the proximity effect.
Solution Approach 2:
The patent applies different winding structures to different locations: the metal plate winding body is positioned at the center while the first and second windings are positioned on opposite sides. This creates a non-uniform spatial distribution of windings that optimizes magnetic coupling while reducing localized current concentration and proximity effect in critical areas.
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 design reduces energy loss by preventing local current density increases in the metal plate winding bodies, enhances magnetic coupling, and decreases leakage inductance, resulting in improved efficiency and reduced surge voltage in the transformer unit.
Implementation Method 1
the voltage input to the primary side coil is transformed and output from the secondary side coil
Implementation Method 2
the current concentrates on portions of the primary side coil and the secondary side coil that are close to each other due to proximity effect. The proximity effect is a phenomenon in which, due to the action of a magnetic field generated by currents flowing through the primary side coil and the secondary side coil, currents flow in a concentrated manner at portions close to each other
Data Source
AI summary
A transformer unit includes a primary side coil and a secondary side coil that are disposed to face each other in a winding axis direction. One of the primary side coil and the secondary side coil includes a metal plate winding body. The other of the primary side coil and the secondary side coil includes a first winding and a second winding, which have a greater number of turns than the metal plate winding body. The first winding and the second winding are arranged on opposite sides of the metal plate winding body in a winding axis direction.