Transformer Preformed Insulation Structure for Compact High Voltage Design
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Solution Overview
Problem
Transformers with bifilar winding arrangements face challenges in maintaining sufficient insulation resistance at high voltages without increasing size, as thicker insulation or greater spacing leads to larger transformer cores and higher leakage inductance.
Innovation Solution
A preformed insulation structure with a minimum defined distance between windings, allowing for a compact transformer design with controlled leakage inductance, where the insulation structure remains dimensionally stable and facilitates easy assembly by wrapping the second winding around it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of insulation material of wires is increased to ensure sufficient insulation resistance at high voltages, then insulation resistance is improved, but the volume of the turns increases leading to larger transformer core size
Solution Approach 1:
The patent introduces a third dimension by placing windings on different levels (stacked arrangement) rather than just increasing spacing in the radial direction. This vertical stacking allows maintaining compact radial dimensions while achieving adequate insulation distance through the axial dimension, thus improving insulation resistance without increasing transformer core volume
Solution Approach 2:
The patent implements nested winding arrangements where windings are positioned in stacked levels within the transformer core. The inner windings are nested within the outer windings axially, creating a compact structure that maintains sufficient insulation distance between high-voltage and low-voltage windings without requiring increased radial spacing or thicker insulation material
2Reliability
If the spacing between windings is increased to ensure sufficient insulation resistance at high voltages, then insulation resistance is improved, but the volume of the turns increases leading to larger transformer core size
Solution Approach 1:
The patent utilizes the axial dimension to create vertical spacing between windings on different levels, rather than increasing radial spacing. This allows achieving adequate insulation distance for high voltage applications while maintaining compact radial dimensions and avoiding increased transformer core volume
3Reliability
If the windings are arranged on different segments along the circumference to increase distance between windings, then insulation resistance is improved, but leakage inductance increases and transformer size increases
Solution Approach 1:
The patent transitions from radial segmentation arrangement to axial stacking arrangement, placing windings on different levels rather than different circumferential segments. This maintains spatial proximity for low leakage inductance while achieving insulation distance through the axial dimension between stacked winding levels
Solution Approach 2:
The nested winding structure positions high-voltage and low-voltage windings in concentric stacked levels around the core, maintaining close coupling for low leakage inductance while the axial separation between levels provides sufficient insulation distance for high voltage applications
Data Source
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AI summary
The present invention relates to a preformed insulation structure for a transformer, a transformer with a preformed insulation structure, and a method for manufacturing a transformer with a preformed insulation structure. For example, a first preformed insulation structure can be configured to be arranged between a first and a second winding of a transformer when the first and second windings are wound around a transformer core of the transformer, wherein the preformed insulation structure can further be configured to space the second winding apart from the first winding and from the transformer core.