WO1998041998A1 - Enroulements de transformateurs et bande conductrice profilee correspondante - Google Patents

Enroulements de transformateurs et bande conductrice profilee correspondante Download PDF

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Publication number
WO1998041998A1
WO1998041998A1 PCT/BG1998/000009 BG9800009W WO9841998A1 WO 1998041998 A1 WO1998041998 A1 WO 1998041998A1 BG 9800009 W BG9800009 W BG 9800009W WO 9841998 A1 WO9841998 A1 WO 9841998A1
Authority
WO
WIPO (PCT)
Prior art keywords
winding structure
transformer winding
primary
insulation
transformer
Prior art date
Application number
PCT/BG1998/000009
Other languages
English (en)
Inventor
George Nachev Nachev
Original Assignee
George Nachev Nachev
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by George Nachev Nachev filed Critical George Nachev Nachev
Priority to AU62863/98A priority Critical patent/AU6286398A/en
Publication of WO1998041998A1 publication Critical patent/WO1998041998A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/323—Insulation between winding turns, between winding layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures

Definitions

  • the present invention relates to transformer windings and wire profiles for making the same, particularly in transformers for resistance welding, where the weight and dimensions of the transformers are critical
  • the present invention is directed to light-weight, self-cooling compact transgun transformers which are integrally mounted to welding guns forming the transgun assembly
  • Such transformers are characterised by windings that are closely coupled together both electrically and thermally, whereby the heat generated in both the primary and secondary windings is carried away by the fluid, flowing through the secondary winding
  • windings that are closely coupled together both electrically and thermally, whereby the heat generated in both the primary and secondary windings is carried away by the fluid, flowing through the secondary winding
  • the primary winding for resistance welding transformers is preferably a set of multi-turn coils made from rectangular profiled wire with generally planar side portions They are wound with each turn of the conductor stacked on top of the previous turn to form a coil with the exposed sides of the conductors lying in two substantially planar portions at each side of the coil
  • the secondary winding is formed preferably from a square-shaped hollow member Each secondary turn is preferably the same size as a primary coil
  • planar primary and secondary windings are interleaved in order to achieve optimum magnetic coupling, minimum leakage fields and low thermal resistance between the sections of the primary and secondary windings They are electrically insulated from each other and from the core in a manner known in the art This winding structure is then positioned around the center leg of a suitable E-shaped core or double C-core to make the transformer
  • the primary sections is formed from rectangular enamelled wires (Fig 1 )
  • Fig 1 The problem with these wires is that it isn't economically feasible to make broad and thin enamelled rectangular wires, which dictate the number of sections of the primary winding in real designs to be preferably 6 or 8
  • some sort of insulation between those sections is needed, occupying space which could be used for windings with larger cross section, hence lower resistance
  • a set of spiral type strip coils may also be utilised whereby such windings have a strip conductor shape which is narrower and thicker than thin foil material
  • the thickness of the copper strip becomes an order of magnitude larger than that of the insulating strip, while the number of insulations between the primary sections is reduced to 1 or 0 (Fig 3 and Fig 7a)
  • the thickness of the flat conductor is between 0,5 and 2 mm, while the insulating strip is around 0 1 mm This achieves a much better space factor than the above mentioned designs while maintaining good thermal coupling between the primary and secondary windings.
  • the objects of the invention are accomplished by winding the primary coils from a flat conductor having an insulating strip and a suitably shaped conductive strip, both strips with essentially equal width, these primary coils being then tightly assembled with the secondary winding and appropriate insulation into a winding structure, and positioned in inductive relationship with a magnetic core to form a transformer.
  • suitable rubber e.g. butyl rubber
  • an appropriate insulation e.g. polyimid foil, polyfol etc.
  • suitable channels are engraved, through which the epoxy can penetrate the space between the insulation and the secondary winding.
  • Fig. 1 shows the standard cross section of enamelled rectangular wires.
  • Fig. 2 is a section of one possible design of the winding structure with full width foil primary winding.
  • Fig. 3 shows one leg of the winding structure when 4 primary coils are interleaved with 2 secondary turns.
  • Fig. 4 shows a primary coil according to the current art.
  • Fig. 5 shows symmetric and asymmetric shapes of the flat conductor according to the present invention.
  • Fig. 6 shows primary coils made from flat conductors according to the present invention.
  • Fig. 7 is a section of one leg of the complete winding structure when 3 primary coils are interleaved with 2 secondary turns. It shows the channels on the secondary winding and the sealing of the outside surfaces of the primary coils.
  • primary coils are wound from a flat conductor having an insulating strip 1 on one side and a flat copper strip 2, whose narrow edges are trapezoidally shaped (Fig. 6). Both the insulating and the conductive strips have essentially equal width. Depending on the quality of the winding jig the successive coil turns will lie exactly on top of each other (Fig. 6a) or have some deviation (Fig. 6b). In either case the insulation between adjacent turns is guaranteed due to the air gap between the edges, even in cases where the insulating strip is somehow misplaced. As the welding transformers are for primary voltages between 220 and 600 V, the voltage between adjacent turns is less than 10 V, so even if there is no additional insulation between them - e.g. epoxy resin - an air gap of 0,1 mm is sufficient guarantee for the proper function of the transformer. At the same time the flat side of the trapezoid has a surface equalling between 60 and 90% of the flat conductor thickness.
  • the absence of protruding insulating strips allows the planar side surfaces of the primary turns 2 to be in almost immediate thermal contact with the adjacent surface of the secondary 5 (Fig. 7b), thus maximising the thermal conductivity between them.
  • the only thermal barrier between the primary coil and the secondary turn is the inevitable electric insulation 9, which is typically around 0,15 mm, or 5 to 20 times less than in existing designs.
  • the edges of the trapezoids are rounded.
  • the distance between the primary coil and the surface of the secondary should be maintained somehow larger to allow the epoxy resin penetrate these volumes 13, replacing the air.
  • a more pronounced trapezoidal form 4 on this side of the flat conductor can be formed, thus minimising the direct thermally conductive contact to the neighbouring members by replacing it with more air.
  • the narrowness of the trapezoid's crest is limited only by mechanical considerations: a too edge-shaped crest can bend or even detach during winding and short-circuit primary turns.
  • a 0,2 - 0,4 mm flat (in reality slightly rounded) crest (Fig. 5b) is considered to be a reasonable trade-off between mechanical strength and poor thermal conductivity.
  • the air gap between successive turns is a sufficient insulation at the envisaged voltages, but to prevent small loose metal particles, which are almost inevitable during actual manufacturing, from migration within the space 12 possibly short-circuiting adjacent primary turns, it is preferred that this surface of the primary coil be fixed with some sort of insulating enamel.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulating Of Coils (AREA)
  • Resistance Welding (AREA)

Abstract

Cet enroulement est constitué d'enroulements primaire et secondaire, isolés les uns des autres, comme l'est la structure du noyau du transformateur. Les enroulements primaires sont constitués d'un élément conducteur plat pourvu d'une bande isolante et d'une bande conductrice dont les cotés à découvert sont de forme trapézoïdale, la largeur des deux bandes étant sensiblement la même. Ces enroulements sont assemblés en spirales serrées avec l'enroulement secondaire et convenablement isolés à l'intérieur de la structure.
PCT/BG1998/000009 1997-03-19 1998-03-12 Enroulements de transformateurs et bande conductrice profilee correspondante WO1998041998A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU62863/98A AU6286398A (en) 1997-03-19 1998-03-12 A transformer winding structure and profiled conductive strip for the same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BG101342 1997-03-19
BG101342A BG62541B1 (bg) 1997-03-19 1997-03-19 Намотка на трансформатор за електросъпротивително заваряване

Publications (1)

Publication Number Publication Date
WO1998041998A1 true WO1998041998A1 (fr) 1998-09-24

Family

ID=3926928

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/BG1998/000009 WO1998041998A1 (fr) 1997-03-19 1998-03-12 Enroulements de transformateurs et bande conductrice profilee correspondante

Country Status (3)

Country Link
AU (1) AU6286398A (fr)
BG (1) BG62541B1 (fr)
WO (1) WO1998041998A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008082805A2 (fr) * 2006-12-27 2008-07-10 General Electric Company Ensemble de transformateur de lampe
CN102364628A (zh) * 2011-07-19 2012-02-29 南通迪皮茜电子有限公司 变压器用线圈及其制造方法
CN106158286A (zh) * 2015-04-27 2016-11-23 台达电子工业股份有限公司 一种带中心抽头的变压器

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE211489C (fr) *
GB790721A (en) * 1955-02-09 1958-02-12 Reynolds Metals Co Aluminium strip suitable for use in electromagnetic windings and method of manufacturing same
US3558803A (en) * 1969-08-26 1971-01-26 Revere Copper & Brass Inc Magnet strip conductor
EP0049444A1 (fr) * 1980-10-06 1982-04-14 Asea Ab Bobine électrique à bandes pour appareils électriques
US4450424A (en) * 1982-05-10 1984-05-22 Mcgraw-Edison Company Electrical insulating system
EP0522475A1 (fr) * 1991-07-10 1993-01-13 ABBPATENT GmbH Elément inductif et son procédé de fabrication
US5501897A (en) * 1993-03-08 1996-03-26 Nitto Denko Corporation Tracking resistant pressure-sensitive adhesive tape

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE211489C (fr) *
GB790721A (en) * 1955-02-09 1958-02-12 Reynolds Metals Co Aluminium strip suitable for use in electromagnetic windings and method of manufacturing same
US3558803A (en) * 1969-08-26 1971-01-26 Revere Copper & Brass Inc Magnet strip conductor
EP0049444A1 (fr) * 1980-10-06 1982-04-14 Asea Ab Bobine électrique à bandes pour appareils électriques
US4450424A (en) * 1982-05-10 1984-05-22 Mcgraw-Edison Company Electrical insulating system
EP0522475A1 (fr) * 1991-07-10 1993-01-13 ABBPATENT GmbH Elément inductif et son procédé de fabrication
US5501897A (en) * 1993-03-08 1996-03-26 Nitto Denko Corporation Tracking resistant pressure-sensitive adhesive tape

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008082805A2 (fr) * 2006-12-27 2008-07-10 General Electric Company Ensemble de transformateur de lampe
WO2008082805A3 (fr) * 2006-12-27 2008-12-04 Gen Electric Ensemble de transformateur de lampe
US7746211B2 (en) 2006-12-27 2010-06-29 General Electric Company Lamp transformer assembly
CN102364628A (zh) * 2011-07-19 2012-02-29 南通迪皮茜电子有限公司 变压器用线圈及其制造方法
CN102364628B (zh) * 2011-07-19 2012-07-04 南通迪皮茜电子有限公司 变压器用线圈的制造方法
CN106158286A (zh) * 2015-04-27 2016-11-23 台达电子工业股份有限公司 一种带中心抽头的变压器

Also Published As

Publication number Publication date
AU6286398A (en) 1998-10-12
BG62541B1 (bg) 2000-01-31
BG101342A (en) 1998-10-30

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