Winding Wire Insulation Wrapping for Compact High-Voltage Transformers
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Solution Overview
Problem
Existing methods for producing winding wires fail to address the challenges of producing winding wires that are not addressed by existing methods, which result in increased transformer height, volume, and material costs due to the use of three-layer insulated winding wires, leading to reduced power density and lower withstand voltage.
Innovation Solution
A method for producing winding wires that involves wrapping an insulating layer around the wire in a perpendicular direction, cutting and twisting the exposed ends, and soldering them to form a compact, flat surface, allowing for automatic processing and reducing the wire diameter while increasing the thickness of the outer insulating layer to three layers, thereby increasing the distance between windings and improving withstand voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-layer insulated Kara line is used to meet safety and insulation requirements, then the withstand voltage is improved, but the wire diameter increases and the transformer volume increases
Solution Approach 1:
The patent changes the insulation structure parameters by using self-adhering insulating tape wrapped in a spiral manner around the wire, creating multiple adhesive bonds along the wire length. This alternative insulation approach achieves the required withstand voltage (3000VAC or higher) while reducing the overall wire diameter compared to traditional three-layer insulated Kara lines, thereby reducing transformer volume.
2Reliability
If a three-layer insulated Kara line is used to meet safety requirements, then the insulation performance is improved, but the material cost increases
Solution Approach 1:
The patent changes the insulation material and structure parameters by replacing the traditional three-layer insulated Kara line with a wire wrapped in self-adhering insulating tape. This approach achieves the required insulation performance (withstand voltage of 3000VAC or higher) while using less material, thereby reducing material cost.
3Volume of stationary object
If the wire diameter is reduced to increase power density, then the transformer volume is reduced, but the withstand voltage between windings decreases
Solution Approach 1:
The patent changes the insulation structure parameters by wrapping self-adhering insulating tape around the wire in a spiral manner with multiple adhesive bonds, creating sufficient insulation thickness even with reduced wire diameter. This allows the transformer volume to be reduced while maintaining the required withstand voltage between windings.
4Ease of manufacture
If traditional winding wire processing methods are used, then the production process is simple, but automatic processing is difficult to realize
Solution Approach 1:
The patent applies preliminary action by pre-coating the insulating tape with adhesive on one surface before wrapping. This preliminary preparation enables the wrapping process to be easily automated, as the adhesive is already in place to secure the tape during automated wrapping operations,从而实现自动加工.
Data Source
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AI summary
A method for producing a winding wire includes providing a wrapping tool (100); fixing two ends of a wire (41, A) on the wrapping tool (100) in an X-axis direction; disposing an edge (E1) of an insulating layer (E) in the X-axis direction on the wire (41, A); wrapping the insulating layer (E) around the wire (41, A) in a Y-axis direction, thereby dividing the wire (41, A) into a first exposed portion (A1), a wrapped portion (A2) and a second exposed portion (A3); cutting the first and the second exposed portions (A1, A3) to form a first exposed end (Aa) and a second exposed end (Ab); performing a twisting process on the first and the second exposed ends (Aa, Ab); and performing a soldering process on the twisted first and the twisted second exposed ends (Aa, Ab) to form a first soldered portion (Aa1) and a second soldered portion (Ab1), thereby forming the winding wire, wherein intervals (F) are respectively left between the first and the second soldered portions (Aa1, Ab1) and opposite ends of the wrapped portion (A2).