Transformer Core Magnetic Lacquer Filling Air Gaps
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Solution Overview
Problem
Transformer cores with air gaps between laminations result in increased magnetic resistance and no-load losses, reducing efficiency and making manual assembly costly, especially in 'Unicore single' and 'Unicore duo' types.
Innovation Solution
A transformer core with bent laminations forming air gaps is impregnated or coated with a lacquer containing magnetic particles, which fills these gaps, reducing magnetic resistance and allowing for automated assembly and improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If air gaps are formed between lamination ends in winding cores, then automated assembly is enabled, but magnetic resistance increases and no-load losses increase
Solution Approach 1:
The invention converts the harmful effect of air gaps (which cause magnetic resistance and energy losses) into a beneficial structure by filling them with magnetic lacquer. The lacquer penetrates the air gaps between lamination ends, transforming the previously harmful air-filled spaces into magnetically conductive paths, thereby reducing no-load losses while maintaining the automated assembly capability of the winding core design
Solution Approach 2:
The invention changes the physical and magnetic parameters of the air gap region by introducing magnetic lacquer with specific magnetic properties. The lacquer modifies the magnetic permeability and conductivity of the air gap space, transforming it from a high-resistance region to a low-resistance magnetic path, thereby reducing overall magnetic resistance and energy losses
2Manufacturing precision
If manual assembly of Unicore single cores is used, then manufacturing precision is maintained, but production cost increases and productivity decreases
Solution Approach 1:
The magnetic lacquer serves a dual function: it fills the air gaps to reduce magnetic resistance and simultaneously acts as an adhesive bonding agent that secures the laminations together. This self-bonding property eliminates the need for manual assembly operations while maintaining structural integrity and manufacturing precision, thereby enabling automated production without sacrificing quality
3Loss of energy
If air gaps are filled with magnetic lacquer, then magnetic resistance is reduced and no-load losses decrease, but manufacturing complexity increases
Solution Approach 1:
The invention uses a liquid magnetic lacquer that can be applied through spraying or dipping methods, allowing the magnetic material to penetrate and fill the air gaps between laminations. The liquid state of the lacquer enables it to flow into narrow gaps, and upon drying, it solidifies to provide both magnetic conductivity and structural bonding, simplifying the overall manufacturing process
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 magnetic particles in the lacquer significantly reduce no-load losses and enhance the core's fill factor, improving transformer efficiency and enabling cost-effective, automated manufacturing of transformer cores.
Implementation Method 1
the core is impregnated or coated at least at the lamination ends of the laminations with a lacquer containing magnetic particles
Implementation Method 2
the magnetic flux is not deflected as much when transitioning from one lamination end through the air gap filled with magnetic lacquer to the next lamination end
Data Source
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AI summary
The invention relates to a core (3) for a transformer, which comprises a multiplicity of bent metal sheets (1) that are all connected to form a structure that surrounds a core opening (4) and forms the core (3), wherein in each case the sheet ends (2) of each metal sheet (1) do not touch one another with the core (3). The metal sheets (1) form, at their respective sheet ends (2) within the core (3) or at a periphery of the core (3), at least one air gap (5) with the core (3), wherein the core (3) is impregnated or coated, at least at the sheet ends (2) of the metal sheets (1), with a coating (6) that contains magnetic particles. The impregnation or coating fills at least the air gaps (5) at the sheet ends (2) of the metal sheets (1). Also provided is a method for producing a transformer having a core (3) according to the invention.