WO2004097864A2 - Dispositif a enroulement - Google Patents

Dispositif a enroulement Download PDF

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Publication number
WO2004097864A2
WO2004097864A2 PCT/US2004/013536 US2004013536W WO2004097864A2 WO 2004097864 A2 WO2004097864 A2 WO 2004097864A2 US 2004013536 W US2004013536 W US 2004013536W WO 2004097864 A2 WO2004097864 A2 WO 2004097864A2
Authority
WO
WIPO (PCT)
Prior art keywords
coil device
insulating layer
wire
primary winding
winding
Prior art date
Application number
PCT/US2004/013536
Other languages
English (en)
Other versions
WO2004097864A3 (fr
Inventor
Guy A. Lestician
Original Assignee
Inventive Holdings Llc
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 Inventive Holdings Llc filed Critical Inventive Holdings Llc
Publication of WO2004097864A2 publication Critical patent/WO2004097864A2/fr
Publication of WO2004097864A3 publication Critical patent/WO2004097864A3/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • 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
    • H01F27/325—Coil bobbins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/04—Arrangements of electric connections to coils, e.g. leads
    • H01F2005/043—Arrangements of electric connections to coils, e.g. leads having multiple pin terminals, e.g. arranged in two parallel lines at both sides of the coil
    • 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
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/263—Fastening parts of the core together
    • 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
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/266—Fastening or mounting the core on casing or support

Definitions

  • transformer, reactor and/or choke applications along with methods for manufacturing such devices.
  • Wound coil products such as choke coils, transformer coils and reactors, have existed for many years. Examples of such products and methods for their
  • Patent No. 4,587,507 to Takayama et al, each of which is incorporated herein by reference in its entirety.
  • a coil device in accordance with a first embodiment, includes a primary winding of multistranded wire that has been wound around a supporting structure, a conductive core positioned both inside and outside the primary winding, a first insulating layer around the primary winding, and at least one securing member that secures the core, supporting structure and primary winding as a coil device unit.
  • the device may include a secondary winding of wire.
  • the secondary wire may optionally be multistranded, and it may be positioned around the primary winding and/or the first insulating layer.
  • a second insulating layer may be positioned around the secondary winding.
  • the conductive core includes members positioned both inside and outside of the primary winding, and the members positioned inside the primary winding provide an air gap. The primary winding and/or the secondary winding may have been wound in a counterclockwise direction.
  • a method of manufacturing a coil device includes winding a multistranded wire around a supporting
  • the method may also include applying an insulating layer to the wire at an entry point and/or an exit point of the supporting member.
  • the winding step may be performed in a counterclockwise direction.
  • the method may also include applying a secondary winding of wire around the supporting member.
  • FIG. 1 is a top plan view of an embodiment of the present inventive
  • FIG. 2 is a side view of an embodiment of the present inventive device
  • FIG. 3 is a top plan view of an exemplary bobbin that may be used
  • FIGs. 4A - 4C provide side, top plan and bottom plan views of an exemplary locking clip.
  • FIG. 5 is a flowchart that shows the steps that may be
  • FIG. 6A is a printout showing an exemplary input signal for
  • FIG. 6B is a printout showing an exemplary output signal.
  • FIGs. 1 and 2 illustrate a top plan view and a side view
  • a bobbin 12 typically made of a plastic or metal material, although other materials are
  • the bobbin 12 includes a plurality of conductive pins 14,
  • FIGs. 1 and 2 illustrate an embodiment where each bobbin 12 has thirteen pins. However, other embodiments may
  • FIG. 3 An example of a bobbin 32 having sixteen pins is shown in FIG. 3.
  • the size of the bobbin may vary in accordance with the invention.
  • Such bobbins may include common commercially-available bobbins, including but not limited to those with common part numbers such as PQ-34, ETD-34, ETD-29, ETD-39 and others, depending on the size of the coil device desired.
  • the coil 16 is made of a multistranded wire, such as that commonly known as litz wire, in which each wire is constructed of individual film insulated wires bunched or braided together in a substantially uniform pattern of twists.
  • the multistranded construction may result in a higher power output than that which may
  • multiple strands of litz wire are wound around the bobbin in an evenly distributed manner.
  • the number and the length of the strands, used will vary depending on the wire gage used, the hardness of the conductive core (described below) that is used, the air gap size in the conductive core, and/or the desired power output and/or inductance.
  • the exemplary number of strands and size of wire for the embodiment shown in FIGs. 1 and 2 is two wires (i.e., twenty individual strands, where each litz wire contains ten individual strands) of litz wire such as 30-gage litz wire
  • the exemplary wire used in the embodiment shown in FIG. 3 is four wires (i.e., forty strands) of litz wire such as 30-gage litz wire.
  • the preferred length of strand for a coil made with ETD-39 bobbin is about eleven feet long (i.e., about 48 turns around the bobbin), although other lengths may be used for this and other bobbins.
  • an ETD-34 or PQ-34 bobbin may use an approximately 8-foot length of #30, 20-stranded litz wire. The length of wire used will vary, but it should be sufficient to allow the wire to substantially fill the bobbin when the bobbin is turned.
  • the wires are maintained slightly taut to allow even distribution, but the wires are not pulled so tightly that the dielectric in the wires breaks down.
  • the winding may be done by turning the bobbin in a counterclockwise direction.
  • a "counterclockwise direction” means the direction viewed when observing the turn of the bobbin from the side opposite that to which the wire is attached as a starting point. This may also be known as “top coming" to those skilled in the art.
  • Each strand of wire in the coil may be electrically connected to a pin 14 on one side of the bobbin 12 as well as to a pin 14 on the other side of the bobbin, such that the starting point is on one side and the end point is on another side of the bobbin.
  • the specific pins used as starting points and ending points may vary. Since litz wire strands are typically grouped, such as in groups of ten strands, all strands may be attached to a single pin on each side of the bobbin, or optionally the groups may be attached to one or more different pins.
  • the electrical connections are preferably made by soldering or another conductive connecting means.
  • An insulating material 20 such as electrical tape or an insulating sheath is preferably applied around the wire where it meets the pins in order to insulate the wire from the pins other than the pin to which electrical
  • the insulating material 20 also prevents the coil from shorting when a voltage is applied to the coil.
  • an insulating and/or securing layer 18, such as electrical tape and/or a varnish may be applied to the outside of the coil in order to secure the coil and/or provide additional insulation. This may be done, for example, by dipping the coil in hot (e.g., approximately 180° F) varnish and then allowing it to air dry. In an embodiment, an insulating layer of tape may be applied and then covered with varnish. Although not required, insulating / securing layer 18 is preferred.
  • a conductive core material is inserted into the bobbin.
  • the core members are preferably made of ferrite, polybutyleneterephtalate or other metal materials
  • the core members may have other shapes, such as rounded "E's" or other shapes that are appropriate for the bobbin.
  • the core members 34 and 36 may meet at a gap 38. If the size of the gap 38 is increased, the resulting inductance can be increased and power output can be decreased. Conversely, if the gap 38 is small, or if core members 34 and 36 touch, inductance is decreased and power output is increased. Thus, the size of the gap may vary depending on the desired
  • FIG. 2 An example of such a securing means is illustrated in FIG. 2 and FIGs. 4 A through 4C. Referring to FIGs. 4 A
  • a locking clip 40 includes a first arm having a tab 42 and a
  • second arm having a receptacle 44.
  • two locking clips made of metal or other relatively firm material are inserted around the core members such that the tab of each locking member engages the receptacle of the other locking member.
  • locking clip may be made of steel or another relatively firm material. Of course, other appropriate securing means, such as fasteners, grips, or even tape, may be used.
  • FIG. 5 is a flowchart that shows exemplary steps in a method of preparing a coil device. Referring to FIG. 5, a group of multistranded wire strands are
  • a layer of tape may also be applied to the center of the bobbin before winding in order to smooth any ridges.
  • the wire is then wound around the bobbin, optionally in a counterclockwise direction, optionally using a winding device such as a Bobbineer TM, in an evenly distributed manner.
  • the wires are not held too tightly during winding so that the wires are not damaged during winding and so that small air gaps are provided in the final coil.
  • An insulating material may also be applied to the wires at the end point (step 56), and the wire ends at each end point may be soldered or otherwise electrically connected to the pins of the bobbin (step
  • the bobbin may not need to include pins, and thus the wire ends may merely be soldered or otherwise connected so act as a single conductive strand.
  • the insulating material may not be required if pins are not used.
  • a secondary winding may be applied on top of
  • the first winding be repeating the process described above.
  • the second winding is typically smaller than the primary winding, and it may be separated from the primary winding by tape or another insulating layer.
  • the secondary winding may also be made of multistranded wire.
  • the secondary winding may also be partially or fully covered by a second insulating layer.
  • the coil may be coated (step
  • the bobbin may optionally be removed after winding, and the core material may simply be placed directly into the core of the coil.
  • An air gap may be left in between the two halves of the conductive core, and the gap can vary depending on the desired characteristics of the device.
  • the device may then be secured (step 64) by an appropriate fastener, tape or other material or mechanism.
  • this construction and method of winding produces a coil device that has improved filtering characteristics, and which in preferred embodiments can transform a distorted signal or a DC or pulsed input signal, such as that illustrated in FIG. 6A, into a substantially sinusoidal signal such as that illustrated in FIG. 6B.
  • the use of multistranded or litz wire also provides improved response times, such as when the coil device is used in connection with a ballast or other circuit for lighting a lamp, including but not limited to ballasts and circuits such as those disclosed in U.S. Patent No. 6,344,717, to Lestician; U.S. Patent No. 5,521,467, to Statnic et al; U.S. Patent No.
  • multistranded litz wire can increase the power output of the device while reducing the current draw as compared to a coil that has been wound in a clockwise direction and/or using conventional wire. It also may allow the device to operate in a manner that is cooler than ordinary chokes or transformers using solid wire. Although secondary windings may also be provided to allow use of the device as a transformer, secondary windings are not required when the present coil device is used as a choke.
  • the coil device can be used as an input or output transformer or a choke in the power circuit for a bulb, lamp, motor or other load.
  • the device may self-adjust to match the inductance of the load, without the need for physically re-winding the coil.
  • embodiments described above can be used in a ballast to control and power a 150-watt bulb as well as a 400-watt bulb.
  • the coil device was used in connection with a ballast controller to light a lamp, and it was found that the device automatically adjusted to a 1-amp current flow for a 150-watt bulb and a 3.4-amp current flow for a 400-watt bulb. Also, when used in a lighting controller the coil device may automatically adjust to the status of the bulb.
  • a bulb when it is cool, it may have a low inductance (such as 400 microhenrys), but when it is hot the inductance decrease (such as to approximately 30 microhenrys), and the coil device can be used for such applications.
  • the coil device when used in a lighting controller I have found that the coil device can be separated from the bulb by a wire distance of as much as 200 feet or more without any significant loss of output.
  • An alternate embodiment of the invention may use a toroidal conductive core, and multistranded or litz wire may be wound around the toroidal core in a counterclockwise direction by hand or by using a mechanical winding device.
  • multistranded wire may reduce the current draw for a load by, for example, as much as 50% or more as compared to solid wire. Thus, heat loss may also be reduced.
  • the toroidal core may be equipped with pins for mounting in a circuit board.
  • Example 1 A bobbin having part no. ETD-34 or PQ-34 serves as the basis for winding a coil device. Approximately eight feet of no. 30 litz wire, having 20 strands, in which two groups of ten strands each are available, are used to wind
  • the wires are wound around the center piece of the bobbin in a counterclockwise direction until the bobbin is substantially filled, just shy of the sides of cores when inserted.
  • Two layers of Mylar tape are applied to the wound wires, and the wires are positioned to exit
  • the starting point wires are soldered to pin 3 and the exit point wires are soldered to pin 11 or 14.
  • Two ferrite cores, such as those having part number ETD-34, are inserted into the bobbin with a central air gap of approximately .01 inch. The resulting
  • the coil device is dipped in varnish, such as type UL108 varnish, at a temperature of approximately 180° F until dry.
  • varnish such as type UL108 varnish
  • the resulting coil device has an inductance of approximately 1.0 mH, although the actual inductance may vary by plus/minus 10 percent embodiments in some embodiments, and in other embodiments it may vary by as much as plus/minus 50 percent.
  • the device may be used to use as a choke in connection with the circuit of, for example, a 150 watt bulb.
  • Example 2 A bobbin having part no. ETD-39 is used to wind approximately 12 feet of number 30 litz wire having four groups of ten strands each. If the bobbin has ridges on its central core, one or two layers of insulating tape are applied around the central core to provide an even core area. A small amount of insulating tape is applied to the wire over the gap between bobbin starting pins 13 and 14. The wires are then wound around the center member of the bobbin in a clockwise direction and exit the bobbin at pin 3, with an insulating layer placed around the wire at the exit point. Two groups of strands of wire are soldered to pins 4 and 5 near the exit point, while two groups of strands of wire are soldered to pins 4 and 5 near the exit point, while two groups of strands of wire are soldered to pins 4 and 5 near the exit point, while two groups of strands of wire are soldered to pins 4 and 5 near the exit point, while two groups of strands of wire are soldered to pins 4 and 5
  • Ferrite cores having part no. ETD39PM60-385 are inserted with an air gap of approximately .03 inch left between the cores.
  • One or two layers of Mylar tape are applied to the coil and the coil is varnish dipped at approximately 180° F and allowed to air dry. The resulting device has an inductance of
  • the unit may be used, for example, to power a 400 watt bulb.
  • a secondary winding may have also been applied to the device.

Abstract

Un dispositif à enroulement comprend un bobinage primaire en fil multibrins qui a été enroulé autour d'une structure de support, un noyau conducteur positionné à l'intérieur et à l'extérieur du bobinage primaire, une première couche isolante placée autour du bobinage primaire et au moins un élément de fixation qui fixe le noyau, la structure de support et le bobinage primaire sous forme d'une unité de dispositif à enroulement. Le dispositif peut également comprendre un deuxième bobinage de fil, tel qu'un fil multibrins. Le dispositif peut être utilisé en tant que transformateur ou bobine d'arrêt autoréglable dans des applications électriques.
PCT/US2004/013536 2003-04-29 2004-04-29 Dispositif a enroulement WO2004097864A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US46631503P 2003-04-29 2003-04-29
US60/466,315 2003-04-29

Publications (2)

Publication Number Publication Date
WO2004097864A2 true WO2004097864A2 (fr) 2004-11-11
WO2004097864A3 WO2004097864A3 (fr) 2005-06-23

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4081776A (en) * 1975-06-16 1978-03-28 Matsushita Electric Industrial Co., Ltd. Transformer with heat conducting laminate
WO1984004625A1 (fr) * 1983-05-16 1984-11-22 Masami Sakurai Transformateur a courant alternatif sans tension
EP0448974A1 (fr) * 1990-03-28 1991-10-02 Siemens Aktiengesellschaft Bobine pour un transformateur
GB2313483A (en) * 1996-05-22 1997-11-26 Samsung Electronics Co Ltd Coils for electromagnetic actuators
US6449178B1 (en) * 1999-06-15 2002-09-10 Matsushita Electric Industrial Co., Ltd. Magnetron drive step-up transformer and transformer of magnetron drive power supply
US20020175798A1 (en) * 2001-05-22 2002-11-28 Dennis Sigl Welding power supply transformer

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4081776A (en) * 1975-06-16 1978-03-28 Matsushita Electric Industrial Co., Ltd. Transformer with heat conducting laminate
WO1984004625A1 (fr) * 1983-05-16 1984-11-22 Masami Sakurai Transformateur a courant alternatif sans tension
EP0448974A1 (fr) * 1990-03-28 1991-10-02 Siemens Aktiengesellschaft Bobine pour un transformateur
GB2313483A (en) * 1996-05-22 1997-11-26 Samsung Electronics Co Ltd Coils for electromagnetic actuators
US6449178B1 (en) * 1999-06-15 2002-09-10 Matsushita Electric Industrial Co., Ltd. Magnetron drive step-up transformer and transformer of magnetron drive power supply
US20020175798A1 (en) * 2001-05-22 2002-11-28 Dennis Sigl Welding power supply transformer

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