WO1996038849A1 - High voltage isolating transformer module - Google Patents
High voltage isolating transformer module Download PDFInfo
- Publication number
- WO1996038849A1 WO1996038849A1 PCT/US1996/008147 US9608147W WO9638849A1 WO 1996038849 A1 WO1996038849 A1 WO 1996038849A1 US 9608147 W US9608147 W US 9608147W WO 9638849 A1 WO9638849 A1 WO 9638849A1
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- WIPO (PCT)
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- transformer
- substrates
- high voltage
- pair
- transformer module
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Classifications
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- 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
- H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
- H01F27/306—Fastening or mounting coils or windings on core, casing or other support
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- 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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F30/00—Fixed transformers not covered by group H01F19/00
- H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
- H01F30/10—Single-phase transformers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F38/00—Adaptations of transformers or inductances for specific applications or functions
- H01F38/16—Cascade transformers, e.g. for use with extra high tension
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F19/00—Fixed transformers or mutual inductances of the signal type
- H01F19/04—Transformers or mutual inductances suitable for handling frequencies considerably beyond the audio range
- H01F19/08—Transformers having magnetic bias, e.g. for handling pulses
- H01F2019/085—Transformer for galvanic isolation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F38/00—Adaptations of transformers or inductances for specific applications or functions
- H01F2038/006—Adaptations of transformers or inductances for specific applications or functions matrix transformer consisting of several interconnected individual transformers working as a whole
Definitions
- the present invention relates generally to transformers, and more specifically to a transformer module for isolating high and low voltage components.
- high voltage transformer 20 includes a 15 two-piece ferromagnetic core 22a and 22b, primary windings 24, a plurality of secondary windings 26a, 26b, . . . 26f, and insulation 28.
- the primary windings are constructed of a continuous conductive wire that is wrapped around the two legs of the core a desired number of turns.
- 26f are each constructed of a continuous conductive wire 20 wrapped around a cylindrical nonconducting spool (not shown) a desired number of turns.
- the plurality of secondary windings surround the primary windings and the core, but are spaced a distance away from the primary windings by intervening insulation 28.
- an alternating voltage applied across the primary winding will be stepped up by the transformer proportionally to the ratio of the number of turns in each secondary winding with respect to the number of turns in the primary winding.
- the transformer in FIGURE 1 also contains a plurality of diodes 30a, 30b, . . . 3 Of that are integrally formed with the transformer and connected in a bridge configuration across the output of a corresponding secondary winding 26a, 26b, . . . 26f.
- a stepped-up and rectified voltage is therefore produced by each secondary winding rectifier pair.
- transformer configuration shown in FIGURE 1 may be readily adapted for low-voltage applications, when the configuration is used for high voltage applications (in the kVolt range), several shortcomings of the design become apparent.
- One disadvantage of the traditional design is that design tolerances in the transformer become very critical. When voltages in the kVolt range are being generated by transformer 20, a first distance 32 between the primary and secondary windings, as well as a second distance 34 between the windings and the external surface of the transformer must be carefully controlled. If the amount of insulation 28 is insufficient for the voltage applied across the insulation, the insulation may break down causing the primary winding to short to the secondary winding and leading to a transformer failure.
- Insulation 28 contains dipoles that will align themselves with the alternating electric field generated as current flows through the winding.
- AC alternative current
- the twisting motion of the dipoles is more pronounced the higher the generated output voltage.
- the twisting of the dipoles heats the insulation and causes the insulation to degrade.
- the resistance of the insulation falls and increases the likelihood that a short will occur.
- the performance of the transformer is compromised and the transformer must be replaced.
- the secondary winding of the transformer typically must have a large number of turns in order to step up the voltage to the desired amplitude. As the number of turns in the secondary winding increases, so does the reflected capacitance of the secondary winding.
- Those skilled in the art will recognize that to efficiently drive a large capacitive load, it is desirable to place an inductor in series with the load. As the reflected capacitance of the secondary winding of the transformer increases, it is therefore necessary to include a progressively larger inductor in the system incorporating the transformer. In addition to becoming prohibitively expensive, the inductor will increase the size of the system incorporating the transformer.
- the present invention is directed to a transformer construction for high voltage applications that overcomes or minimizes the above-mentioned disadvantages.
- the present invention provides a high voltage isolating transformer module having high voltage components that are physically and electrically isolated from low voltage components.
- the high voltage components are mounted on a pair of inner high voltage substrates, and the low voltage components are mounted on a pair of outer low voltage substrates.
- Multiple transformers are mounted between the substrates in a single high voltage transformer module.
- Each transformer has a pair of primary windings, a ferromagnetic core, and a pair of secondary windings.
- the core of each transformer is split, half being attached to each of the low voltage substrates, with two legs of each half abutting two corresponding legs of the other half.
- a cylindrical primary winding is wrapped around each leg of the core.
- the low-voltage substrates are separated a fixed distance apart by having their margins fitted in slots of a casing.
- the pair of secondary windings of each transformer stage is attached to the pair of high voltage substrates.
- the pair of high voltage substrates is further formed with a plurality of holes so that, when mounted in the casing between the low voltage substrates, the core and primary windings of each transformer are encased by the secondary windings of each transformer.
- an AC voltage applied across the primary winding induces a stepped-up or stepped-down voltage across the secondary winding.
- a construction that ensures accurate and appropriate spacing of the high voltage and low voltage substrates is disclosed.
- Each substrate is mounted in a set of slots constructed in a bottom casing.
- the slots lock the substrates in a desired position and define an appropriate spacing between adjacent substrates.
- the cavities formed between each substrate are then filled with insulation having a high breakdown voltage.
- the high voltage components are electrically isolated from the low voltage components to a degree sufficient to prevent shorting.
- the outputs from each transformer may be connected to a rectifier.
- the rectifiers are then connected in cascode so that the voltage produced by each transformer/rectifier pair is summed with the other rectified outputs to generate a total output voltage for the high voltage transformer module.
- the number of transformers in each high voltage transformer module may be varied to suit a particular application. Transformers may be added to generate a greater total output voltage, or transformers may be eliminated to generate a smaller total output voltage.
- the flexibility of the design allows an output voltage range to be closely tailored to produce a desired voltage necessary for the application.
- FIGURE 1 is an axial cross section of a representative prior art single stage transformer
- FIGURE 2 is a top perspective of a high voltage transformer module formed in accordance with the present invention with parts broken away;
- FIGURE 3 is a schematic diagram of the high voltage transformer module of FIGURE 2;
- FIGURE 4 is a top perspective of two stages of the high voltage transformer module with the component parts shown in exploded relationship;
- FIGURE 5 is a fragmentary perspective of a single stage of the high voltage transformer module;
- FIGURE 6 is a top perspective of two stages of a second embodiment of the high voltage transformer module with the component parts shown in exploded relationship;
- FIGURE 7 is a top perspective of a third embodiment of the high voltage transformer module.
- FIGURE 8 is a top perspective of a winding and spool construction used in the high voltage transformer module. Detailed Description of the Preferred Embodiment
- a high voltage transformer module 50 constructed in accordance with the present invention includes a bottom casing having a left end wall 54, a right end wall 56, a bottom wall 58, a front wall 60, and a back wall 61.
- a cover plate 52 is fitted to the top of the bottom casing. Cover plate 52 may be permanently sealed to the bottom casing, or attached with fasteners to allow access to the inside of module 50 through the top. The walls that form the bottom casing are sealed so that fluid contained within the module will not leak out. Similarly, the seam between the cover plate and the bottom casing may be sealed. If a pressure build-up is expected within module 50, vents 88 may be incorporated in the cover plate to allow gasses to escape during operation.
- the cover plate and bottom casing of the module are constructed of a nonconductive material having a high breakdown voltage. In a preferred embodiment of the invention, the module casing is constructed of phenolic resin.
- transformers Contained inside and integral with module 50 are multiple high voltage transformers.
- the term "transformer” means an electrical device which, by electromagnetic induction, transforms electrical energy from one or more circuits to one or more other circuits at the same frequency but usually at a different voltage and current value.
- each of the transformers is connected to a rectifier and the output voltages generated by each transformer/rectifier pair are summed to produce a total output voltage for the high voltage transformer module.
- the electrical connections between transformers and rectifiers may be better understood with reference to FIGURE 3.
- FIGURE 3 is a schematic of a preferred embodiment of the module that consists of a number of stages 90a, 90b, . . .
- each stage including a transformer 92a, 92b, . . . 92n and a rectifier 102a, 102b, . . . 102n.
- first stage 90a each of the other stages in the transformer module is constructed in a similar manner. The discussion below therefore applies equally to stages 90b, 90c, . . . 90n.
- transformer 92a In first stage 90a, transformer 92a consists of a primary winding 94a, a core 96a, and a secondary winding 98a.
- the primary winding 94a of the transformer is connected to a pair of input terminals 84a, allowing a voltage to be applied across the primary winding.
- One source of the voltage may be an alternating current (AC) source 99a, shown diagramatically in broken line.
- AC alternating current
- the operation of transformer 92a is well known to those skilled in the art of power supplies.
- An AC voltage applied across the input terminals 84a is stepped up or down according to the ratio of the number of turns in the secondary winding to the number of turns in the primary winding.
- rectifier 102a is a full wave bridge constructed of four diodes. The rectifier rectifies the stepped-up AC output voltage from transformer 92a and produces a rectified direct current (DC) output voltage across the output of the rectifier.
- DC direct current
- Stages 90b, 90c, . . . 90n are constructed identically to first stage 90a.
- the outputs from bridge rectifiers 102a, 102b, . . . 102n in each stage are cascoded so that the voltage produced at the output of each stage is summed with all the other stages and the sum output voltage provided on a pair of output terminals 86.
- the output voltage from the preferred embodiment of the high voltage transformer module is therefore equivalent to the sum of the voltage across each of the stages. For example, if each of the stages produced an output voltage of 2,000 volts, and ten stages were cascoded, the output voltage produced by the high voltage transformer module would be 20,000 volts.
- each stage 90a, 90b, . . . 90n are contained within high voltage transformer module 50.
- Each end wall 54 and 56 has a pair of inwardly opening lower slots or grooves 70 and 71, and a pair of inwardly opening upper slots or grooves 72 and 73. All of the slots are parallel, and each slot opens toward and is aligned with a corresponding slot on the opposing end wall.
- Lower slots 70 on the left end wall and the right end wall support a low voltage substrate 62
- lower slots 71 on the left end wall and the right end wall support a high voltage substrate 64.
- low voltage substrate 62 is parallel with high voltage substrate 64 over the length of module 50.
- upper slots 72 on the left end wall and the right end wall support a high voltage substrate 66
- upper slots 73 support a low voltage substrate 68.
- high voltage substrate 66 is parallel with low voltage substrate 68.
- the high and low voltage substrates are each constructed of nonconductive material having a high breakdown voltage. In a preferred embodiment of the invention, the substrates are constructed of phenolic resin.
- the slots formed in the end walls maintain the high voltage and low voltage substrates at a fixed distance from each other and from the bottom and the top of the module casing. As a result, numerous cavities are formed within module 50.
- An inner cavity 74 is formed between the high voltage substrates 64 and 66. The distance between the high voltage substrates is fixed by the position of slots 71 and 72 thereby defining the size of the inner cavity.
- a cavity is also formed between each high voltage and low voltage substrate pair.
- a first intermediate cavity 76 is formed between high voltage substrate 64 and low voltage substrate 62.
- a second intermediate cavity 78 is formed between high voltage substrate 66 and low voltage substrate 68.
- first intermediate cavity 76 The distance between slots 70 and 71 defines the upright dimension (thickness) of first intermediate cavity 76
- second intermediate cavity 78 defines the upright dimension (thickness) of second intermediate cavity 78.
- Additional outer cavities are formed between each low voltage substrate and the top or bottom of the module.
- a first outer cavity 80 is formed between low voltage substrate 62 and bottom wall 58 of module 50.
- a second outer cavity 82 is formed between low voltage substrate 68 and cover plate 52 of module 50.
- the thickness of the first outer cavity is fixed by the distance between lower slots 70 and the bottom of the module, and the thickness of the second outer cavity is fixed by the distance between upper slots 73 and the top of the module.
- the slots are accurately formed in the side walls so that the high voltage substrates and the low voltage substrates are maintained an equal distance apart over the length of the module. If necessary, additional slots or other support may be incorporated in the front wall or the back wall of the module to ensure that appropriate spacing is maintained between the high and low voltage substrates. It will also be appreciated that once left end wall 54 and right end wall 56 are fixed in place, the substrates are locked in position between each wall. The module may be turned or moved without concern that the distance between the high and low voltage substrates will change due to the motion of the module. Other supports could be envisioned that would also fix the substrates with respect to each other. For example, brackets or other members could be affixed to the walls of the casing and to the substrates. Alternately, a freestanding support structure could be constructed that would fix the substrates within the case but away from the walls. Any support structure must maintain a desired distance between the substrates, as well as between the substrates and surrounding components or case.
- Module 50 shown in FIGURE 2 contains stages 90a, 90b, . . . 90n. In a preferred embodiment discussed below, ten stages are incorporated in each module. It will be appreciated, however, that the number of stages may be increased or reduced depending on the voltage needed for a particular application.
- each stage of the transformer has a corresponding pair of input terminals 84a, 84b, . . . 84n, wherein an input voltage may be applied across the transformer. In the representative module shown, the input terminals are mounted on the cover plate of the module.
- Module 50 also contains a pair of output terminals 86 that are located on the cover plate of the module. The voltage applied across each stage of the high voltage transformer module is stepped up and summed with the other stages to produce an output voltage across output terminals 86. While output terminals 86 are shown mounted on the cover plate of module 50, the output terminals may similarly be mounted at any point on module 50 that is conveniently accessible.
- FIGURE 4 is a top perspective of first stage 90a and second stage 90b of the high voltage transformer module with the components shown in exploded relationship.
- FIGURE 5 is a fragmentary view of last stage 90n, with the component parts assembled and mounted on the high and low voltage substrates.
- the discussion below focuses on the construction of first stage 90a, but it will be appreciated that the description of the first stage applies equally to the other stages in the transformer module.
- the transformer in first stage 90a consists of a first core 140a mounted on low voltage substrate 62 and a second core 142a mounted on low voltage substrate 68.
- Each core is substantially “U” shaped, with a base or web 146a that is connected to the substrate and two legs 144a that extend outward, perpendicularly from the substrate.
- each leg is substantially cylindrical.
- the legs of first core 140a and second core 142a have approximately the same cross-section so that the inner ends of the cores abut contiguously when they are brought together as shown in FIGURE 5.
- the cores are manufactured of a ferromagnetic material, in a preferred embodiment U64, 3C80 manufactured by Philips.
- Primary windings 148a and 150a are positioned over cores 140a and 142a.
- the primary windings may be constructed using any of a number of different techniques.
- the primary windings are constructed of a number of turns of conductive wire that are wrapped around tubular nonconductive spools 151a.
- the nonconductive spools may be formed of electrically insulating and non-magnetic material such as nylon or rynite.
- the nonconductive spools are sized to fit snugly over the legs of cores 140a and 142a, and to extend from the base of one core to the base of the other.
- the number of turns of wire that are wrapped around the nonconductive spool is determined by the desired amount of voltage increase that is to be generated by each transformer.
- the primary winding has 90 turns.
- the wire used to manufacture the primary winding must be selected so that it is sufficient to carry the current that is expected to flow through the primary winding.
- a suitable wire that may be used to construct the primary winding has a gauge of AWG No. 12.
- the wire around primary winding 148a and primary winding 150a is continuous, so that current will flow first through one winding and then through the other. It will be appreciated that various other techniques for constructing primary windings 148a and 150a are well known in the art of manufacturing transformers.
- the wire in primary windings 148a and 150a completely surrounds the legs of U-shaped cores 140a and 142a. Moreover, the cores and the primary windings of each stage are each mounted on low voltage substrates 62 and 68, isolating the low voltage components from the high voltage components as described in additional below.
- the cores and the primary windings on the cores extend through the components that are attached to the high voltage substrates, i.e., secondary windings 160a and 162a.
- the secondary windings may be manufactured using any of a number of different techniques.
- the secondary windings are constructed of a number of turns of conductive wire that are wrapped around a tubular nonconductive spool 161a. The wire forming the secondary winding 160a and 162a is continuous such that current flowing through secondary winding 160a will subsequently flow through secondary winding 162a.
- the nonconductive spools are sized so that primary windings 148a and 150a fit inside the spools, with sufficient room to create an annular space between the primary windings and the secondary spools.
- the number of turns of wire that are wrapped around each nonconductive spool to make the secondary windings is determined by the desired amount of voltage increase that is to be generated by each stage.
- the secondary winding has 550 turns.
- the transformer therefore steps up the input voltage by a ratio of 550:90.
- the wire used to manufacture the secondary winding must be selected so that it is sufficient to carry the current that will flow through the secondary winding. Suitable wire that may be used to construct the secondary winding has a gauge of AWGNo. 36.
- a plurality of holes 152a, 154a, 156a, and 158a are integrally formed in high voltage substrate 64 and high voltage substrate 66.
- Each hole is approximately the same size as the inner diameter of the nonconductive spool that is used to construct the secondary windings.
- Each secondary winding spool is aligned over the associated hole so that, when the components on the high voltage substrates are assembled, a cylindrical space extends from high voltage substrate 64 through the respective secondary winding and through high voltage substrate 66.
- the cylindrical space allows the primary windings to be suspended within the secondary windings.
- Primary winding 148a will therefore extend through hole 152a, secondary winding 160a, and hole 154a.
- primary winding 150a will extend through hole 156a, secondary winding 162a, and hole 158a.
- the components are mounted on the high voltage and the low voltage substrates so that the axes of the primary and secondary windings are aligned, forming a uniform annular cavity between each primary and secondary winding. The relative spacing of all the components will be discussed in further detail below.
- Attached to high voltage substrate 66 are four diodes 164a, 166a, 168a, and 170a, that collectively form full wave bridge rectifier 102a.
- the diodes are electrically connected to the secondary winding so that the voltage generated across the secondary winding is applied across the two input terminals of the bridge rectifier.
- the bridge rectifier 102a is connected in cascode with bridge rectifiers 102b, 102c, . . . 102n from each of the other stages so that the voltages produced across the output of each of the rectifiers are summed. While the preferred diode layout shown in FIGURE 4 has the diodes surrounding holes 154a and 158a on substrate 66, it will be appreciated that the diodes may be positioned elsewhere on high voltage substrates 66 or on high voltage substrate 64.
- each stage on high voltage substrates 64 and 66 When assembled, the high voltage components of each stage on high voltage substrates 64 and 66 are isolated from the low voltage components on low voltage substrates 62 and 68.
- the secondary windings of each transformer and the full bridge rectifiers of each stage are mounted on the high voltage substrates, and the primary windings and the cores of each transformer are mounted on the low voltage substrates. Additional components may be added to the high or low voltage substrates, depending on their operating voltages.
- the construction of module 50 and the inclusion of the transformer therefore isolates the components both physically and electrically.
- each cavity in module 50 is filled with insulation having a high electrical breakdown voltage.
- each cavity is filled with a liquid, preferably mineral oil or silicon oil. It will be appreciated, however, that other types of materials may be used to fill the cavities, including cast insulation, gasses, or compressed gasses such as SFg. Sufficient liquid or other material is added to module 50 so that inner cavity 74, intermediate cavities 76 and 78, and outer cavities 80 and 82 are filled. The insulation completely surrounds the components of each stage, and isolates the high voltage substrates from the low voltage substrates.
- the annular cavity between the primary winding and the secondary winding is filled with the insulation to isolate the high voltage components from the low voltage components.
- the material is selected to provide sufficient isolation so that the expected voltage generated within each stage and throughout the high voltage transformer module will not short between the high voltage and the low voltage components. Additionally, the high or low voltage components should not short with the casing of the module.
- a first path 180 is defined as the distance between the primary windings and the secondary windings of each transformer, or the distance between the secondary windings and the core of the transformer. The distance is dictated by the number of stages in the transformer, and the maximum output voltage that is to be generated. It will be appreciated that the voltage across the rectifier at each stage increases until the last stage in the chain. If, for example, 20,000 volts were to be generated by the cascode connection often stages, each stage may be responsible for generating 2,000 volts. However, the voltage potential between the last stage and ground would be equivalent to 20,000 volts.
- the length of first path 180 is therefore dictated by the 20,000 volt limitation, and may be determined by dividing the expected maximum voltage by the breakdown voltage of the insulation filling the annular space. The calculated length will be the same as the length determined by dividing the expected maximum voltage by the breakdown voltage of the insulation filling the space between the secondary winding and the core.
- the insulation must be at least two to three times the expected maximum voltage, because the electric field is not uniform between the primary and secondary windings.
- a first path length 180 of approximately 5 mm would be sufficient to prevent breakdown in a 20 kVolt high voltage transformer module having stages connected in cascode. It will be appreciated that in FIGURE 2 the low voltage stages on the right side of the figure progressively increase to the higher voltage stages on the left side of the figure. Theoretically, the first path length between the primary and secondary windings in each stage may therefore be unequal, with the lower voltage stages having a shorter first path length than the higher voltage stages. For convenience in construction, however, the first path length between the primary and secondary windings in each stage is uniformly set to the distance between the windings in the last stage. This provides sufficient distance to ensure that no shorting occurs between any of the components.
- a second path 182 is defined as the distance between the low voltage substrate and the high voltage substrate.
- the substrates must be suspended a sufficient distance apart so that a potential generated across the surface of each substrate will not short to the other substrate.
- the distance is determined by calculating the maximum voltage to be generated by the high voltage transformer module, and dividing by the breakdown voltage of the intervening insulation. As calculated above, if the total output voltage is 20 kVolt and the substrates are separated by mineral oil, the substrates should be positioned a minimum of 5 mm apart.
- a third path 184 is defined as the distance between the low voltage substrate and the exterior case. Because the low voltage substrate will be at or near a very low potential, the path between the low voltage substrate and the outer case may typically be shorter than the other paths. In a preferred embodiment of the invention, the third path is approximately 2 mm.
- a fourth path 186 (represented as a dashed line) is defined as the distance from the secondary winding to the core, in a path extending across the surface of the high voltage substrate, across the surface of the wall of the bottom casing, and across the surface of the low voltage substrate. Because the breakdown voltage across the surface of the substrates and casing is typically lower than the breakdown voltage of the insulation, fourth path 186 must be substantially longer than the other paths. To increase the fourth path length, additional slots or grooves 188 and 190 are cut into the left and right end walls to increase the distance that the voltage must drop across the surface of the walls. In the preferred embodiment, the breakdown voltage across the surface of the compound forming the substrates is on the order of 200-300 volts/mm.
- FIGURE 6 A second embodiment of high voltage transformer module 50 is shown in FIGURE 6. It will be appreciated that the preferred embodiment of the transformer module, having a pair of high voltage substrates and a pair of low voltage substrates, is simple to construct. The transformer components are merely fastened onto the appropriate substrates, and the substrates "sandwiched" together to complete each module. In the second embodiment of the module represented in FIGURE 6, only a single low voltage substrate 200 and a single high voltage substrate 202 are used to mount each transformer stage. The component parts are similar to the preferred embodiment of the transformer module, with each transformer comprising a two-part core 204a and 206a, primary windings 208a and 210a, and secondary windings 212a and 214a.
- the primary windings are positioned over the core and mounted to the low voltage substrate, and the secondary windings are mounted to the high voltage substrate.
- the core halves must be fixed to each other or to the low voltage substrate.
- lower core 204a is mounted on the low voltage substrate.
- the lower core is substantially "U" shaped, with a base 216a that is connected to the substrate and two legs 218a and 220a that extend outward, perpendicularly to the substrate.
- the upper core is substantially linear, and bridges the distance between each leg of the lower core.
- Upper core 206a must be attached to lower core 204a after the high voltage substrate is appropriately positioned over the low voltage substrate.
- the configuration shown in the second embodiment therefore adds somewhat to the complexity in constructing the high voltage transformer module.
- FIGURE 7 A third embodiment of a high voltage transformer module 300 is shown in FIGURE 7. Although similar in construction to the preferred embodiment, the third embodiment incorporates many refinements that simplify the assembly of the high voltage transformer module.
- a pair of low voltage substrates 302 and 304 surround a pair of high voltage substrates 306 and 308.
- the low voltage substrates are attached to, and fixed at a distance from, the high voltage substrates by a number of standoff assemblies 310.
- each standoff assembly comprise a bolt 312, spacers 314, 316, 318, and a nut 320.
- the spacers 314, 316 and 318 are nonconductive tubes.
- bolt 312 is inserted through a hole in high voltage substrate 302, through spacer 314, through a hole in substrate 306, through spacer 316, through a hole in substrate 308, through spacer 318, and finally through a hole in substrate 304.
- the assembly is then secured by the attachment of nut 320 to the bolt.
- the spacing between the substrates is maintained by the spacers 314, 316, and 318 between the substrates.
- the size of each of the spacers is selected to ensure that appropriate spacing is maintained between all of the substrates.
- one standoff assembly is incorporated into the high voltage transformer module at each corner of the module.
- each of the stages comprises a core 330a, 330b mounted on the low voltage substrates 302 and 304.
- Primary windings 332a and 332b are positioned over cores 330a and 330b.
- Secondary windings 334a and 334b are mounted between the high voltage substrates 306 and 308. The secondary windings surround the primary windings and the cores so that current flowing through the primary winding will induce a stepped-up voltage in the secondary winding. It will be appreciated that the construction of each transformer stage may further be varied as discussed in detail above.
- the size of the nonconductive spools used to manufacture the primary and the secondary windings is fixed due to the number of turns that must be incorporated in each of the windings.
- the high voltage substrates and the low voltage substrates are therefore shaped to maximize the number of components that may be contained within the form factor embodied by the high voltage transformer module.
- the high voltage and low voltage substrates are shaped so that their cross section resembles a square wave in appearance.
- a representative cross section of the substrate may be seen in FIGURE 7 in the edge of low voltage substrate 302.
- the outer portions 340 and 348 of the low voltage substrate are constructed in the same plane with the center portion 344 of the substrate. Two raised portions 342 and 346 are located between the outer and center portions.
- the distance between the low voltage substrates is increased.
- the greater distance between the low voltage substrates accommodates the size of the primary transformer windings positioned between the two raised portions.
- the two raised portions also create a channel 350 that runs the length of the substrate between the two raised portions.
- Low voltage components can be mounted within the channel 350 in a manner so that they do not protrude above the raised portions 342 and 346.
- the stepped substrate construction minimizes the overall size of the high voltage transformer module by providing sufficient substrate space so that low voltage components do not have to be mounted on the raised portions 342 and 346.
- a similar stepped construction is used for the high voltage substrates 306 and 308 to create additional space for the mounting of high voltage components.
- the third embodiment of the high voltage transformer module is constructed with two parallel rows of transformer stages.
- the use of two parallel rows, rather than a single row, further minimizes the overall size of the high voltage transformer module.
- the transformer rows are separated by a sufficient distance that varies depending on the anticipated operating voltage. While two rows are shown in the third embodiment, it will be appreciate that the transformer module construction can be expanded to accommodate additional transformer rows.
- the high voltage transformer module may be constructed with nine transformer stages arrayed in a 3x3 grid.
- the high voltage transformer module 300 may therefore be mounted without a case near the components of the particular application.
- the cavities between the high and low voltage substrates are filled with a nonconductive material.
- a liquid insulation such as mineral oil
- the high and low voltage substrates are vertically mounted within the case containing the liquid. That is, the high voltage transformer module 300 should be rotated 90° from the horizontal position shown in FIGURE 7.
- the liquid will be allowed to circulate within the case during operation of the high voltage transformer module.
- the liquid insulation is heated during module operation, causing the liquid to rise between the low and high voltage substrates until it reaches the top of the case. At the top of the case, the liquid cools and is recirculated within the case.
- Additional cooling slots 359 may also be formed in the low voltage substrates to allow circulating insulation to contact and cool the transformer cores. It will be appreciated that in certain applications additional cooling may be required, such as by pumping the liquid insulation through the high voltage transformer module with a pump or providing an external cooling means for the liquid insulation. Most applications will not, however, require such additional cooling methods. As discussed above, one of the advantages of the disclosed transformer module construction is the ability to quickly assemble the module with minimal labor.
- the assembly of the third embodiment of the high voltage transformer module 300 is further simplified by the addition of conductive bridges between each substrate pair.
- the low voltage substrates 302 and 304 are electrically connected by a plurality of conductive bridges 360.
- the high voltage substrates 306 and 308 are similarly connected by a plurality of conductive bridges 362.
- the use of conductive bridges simplifies making electrical connections between the components contained on the low voltage substrate pairs and the high voltage substrate pairs.
- the conductive bridges are banana plugs.
- Plug members 364 are fixed on low voltage substrate 302, and corresponding sockets 366 are fixed on low voltage substrate 304.
- plug members 368 are fixed on high voltage substrate 306 and corresponding sockets 370 are fixed on high voltage substrate 308.
- the portions of the conductive bridges are each fixed to the respective substrate prior to assembly of the high voltage transformer module. Assembly of the module entails securing the four substrates together with the standoff assemblies.
- the plug of each conductive bridge is automatically brought into mechanical and electrical contact with the corresponding socket. Electrical connections between the substrates are therefore automatically made without having to solder wires or use other labor-intensive connection methods.
- the width of the high voltage substrates 306 and 308 is less than the width of the low voltage substrates 302 and 304. The reduced width allows the conductive bridges to span the distance between the low voltage substrates without coming into contact with the high voltage substrates.
- the construction of the high voltage transformer module disclosed herein provides significant advantages in assembly time over those constructions known in the prior art. The automatic positioning of the substrates at appropriate distances from each other, and the automatic alignment and completion of electrical connections between the substrates greatly improves the module assembly time. The assembly time is further improved with the transformer spool construction shown in FIGURE 8.
- FIGURE 8 is a perspective view of a spool 380 that may be used to construct the primary or secondary windings in a transformer stage.
- the spools are nonconductive and formed of electrically insulating and nonmagnetic material such as nylon or delrin.
- the spool is constructed with a first tab 382 and a second tab 384 that protrude from the end of the spool in a plane that is parallel with the spool end.
- Each tab is integrally formed with the spool, and constructed of the same material as the spool.
- a conducting pad 386 is constructed on each tab, oriented to face the substrate abutting the end of the spool.
- the conductive pads are electrically connected to a winding 388 that surrounds the spool.
- each end of the winding is soldered to the conductive pad after the winding is wrapped around the spool. An electrical path is therefore created between the two conductive pads on the spool through the winding.
- the high and low voltage substrates in the high voltage transformer module are constructed with similar conductive pads on the side of each substrate facing the spool.
- the spools are appropriately aligned on a lower substrate.
- the alignment may be done by visual markings, alignment ridges, or other similar structures that correctly orient the spool on the substrate.
- the conductive pads on the substrates are brought into contact with the conductive pads on the spool.
- An electrical connection is thereby completed between the substrates and the spool winding.
- appropriate circuitry may then be coupled via conductive traces on the substrates to connect the multiple transformer stages as discussed above.
- the spool construction disclosed in FIGURE 8 therefore decreases the assembly time by allowing a manufacturer to electrically connect with the transformer windings without having to individually wire each of the transformer windings to the substrates.
- a primary advantage is that the number of stages that may be incorporated in each module may be varied to produce a desired output voltage.
- the module may be expanded to contain up to twenty transformer stages. A user may therefore select a module design which produces an appropriate output voltage for the user's particular application.
- An additional advantage of the module disclosed herein is that components coupled to the transformer in each stage of the module may be mounted on an appropriate substrate depending on their operating voltage. If they are connected to the primary winding of each transformer the components may be mounted on the low voltage substrates, and if connected to the secondary winding of each transformer, they may be mounted on the high voltage substrates. Unlike the prior art designs which mounted the high and low voltage components on the same substrate, the present design ensures that the high voltage components will be electrically as well as physically isolated from the low voltage components.
- a further advantage of the preferred construction disclosed herein is that the total output voltage produced by the high voltage transformer module is divided into a number of lesser voltages produced by each stage.
- the reduced voltage that must be generated by each transformer improves the lifespan of the transformer insulation by reducing the twisting of the insulation dipoles.
- the reduction in the amount that each transformer must step-up the input voltage also reduces the reflected capacitance of the secondary winding.
- a smaller inductor may therefore be placed in series with the secondary winding of each transformer stage, reducing the size of the module.
- each transformer/rectifier pair is connected in cascode to produce a maximum output voltage from the module.
- separate output terminals may be provided for each transformer so that they may be individually used in a circuit requiring multiple transformers to step-up or step-down a number of voltage sources.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002222809A CA2222809C (en) | 1995-06-02 | 1996-05-31 | High voltage isolating transformer module |
EP96916846A EP0871966A1 (en) | 1995-06-02 | 1996-05-31 | High voltage isolating transformer module |
JP8536692A JPH11506268A (en) | 1995-06-02 | 1996-05-31 | High voltage isolation transformer module |
AU59586/96A AU696671B2 (en) | 1995-06-02 | 1996-05-31 | High voltage isolating transformer module with substrates separated by a fixed distance |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/460,072 | 1995-06-02 | ||
US08/460,072 US5594402A (en) | 1995-06-02 | 1995-06-02 | High voltage isolating transformer module |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1996038849A1 true WO1996038849A1 (en) | 1996-12-05 |
Family
ID=23827302
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1996/008147 WO1996038849A1 (en) | 1995-06-02 | 1996-05-31 | High voltage isolating transformer module |
Country Status (7)
Country | Link |
---|---|
US (2) | US5594402A (en) |
EP (1) | EP0871966A1 (en) |
JP (1) | JPH11506268A (en) |
CN (1) | CN1190486A (en) |
AU (1) | AU696671B2 (en) |
CA (1) | CA2222809C (en) |
WO (1) | WO1996038849A1 (en) |
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US5594402A (en) * | 1995-06-02 | 1997-01-14 | International Power Group, Inc. | High voltage isolating transformer module |
US6476207B1 (en) * | 1998-06-11 | 2002-11-05 | Chiron Corporation | Genes and gene expression products that are differentially regulated in prostate cancer |
US8299885B2 (en) | 2002-12-13 | 2012-10-30 | Volterra Semiconductor Corporation | Method for making magnetic components with M-phase coupling, and related inductor structures |
US7965165B2 (en) * | 2002-12-13 | 2011-06-21 | Volterra Semiconductor Corporation | Method for making magnetic components with M-phase coupling, and related inductor structures |
US8237530B2 (en) * | 2009-08-10 | 2012-08-07 | Volterra Semiconductor Corporation | Coupled inductor with improved leakage inductance control |
US7898379B1 (en) | 2002-12-13 | 2011-03-01 | Volterra Semiconductor Corporation | Method for making magnetic components with N-phase coupling, and related inductor structures |
US7498920B2 (en) | 2002-12-13 | 2009-03-03 | Volterra Semiconductor Corporation | Method for making magnetic components with N-phase coupling, and related inductor structures |
US8102233B2 (en) * | 2009-08-10 | 2012-01-24 | Volterra Semiconductor Corporation | Coupled inductor with improved leakage inductance control |
US7352269B2 (en) | 2002-12-13 | 2008-04-01 | Volterra Semiconductor Corporation | Method for making magnetic components with N-phase coupling, and related inductor structures |
US6972967B2 (en) * | 2003-02-20 | 2005-12-06 | Avaya Technology Group | EMC/ESD mitigation module |
US7212406B2 (en) * | 2004-09-01 | 2007-05-01 | Rockwell Automation Technologies, Inc. | Cooling of electrical components with split-flow closed-end devices |
US7889041B2 (en) * | 2007-11-05 | 2011-02-15 | Schweitzer Engineering Laboratories, Inc. | Systems and methods for forming an isolated transformer |
LV13752B (en) * | 2008-04-22 | 2008-07-20 | Innovia Sia | Modular transformer |
US9019063B2 (en) | 2009-08-10 | 2015-04-28 | Volterra Semiconductor Corporation | Coupled inductor with improved leakage inductance control |
US8988178B2 (en) * | 2010-07-05 | 2015-03-24 | Schlumberger Technology Corporation | Downhole inductive coupler assemblies |
KR101735645B1 (en) * | 2010-11-22 | 2017-05-15 | 삼성전자주식회사 | Inductor and transformer |
US9373438B1 (en) | 2011-11-22 | 2016-06-21 | Volterra Semiconductor LLC | Coupled inductor arrays and associated methods |
US10128035B2 (en) | 2011-11-22 | 2018-11-13 | Volterra Semiconductor LLC | Coupled inductor arrays and associated methods |
US9263177B1 (en) | 2012-03-19 | 2016-02-16 | Volterra Semiconductor LLC | Pin inductors and associated systems and methods |
US9691538B1 (en) | 2012-08-30 | 2017-06-27 | Volterra Semiconductor LLC | Magnetic devices for power converters with light load enhancers |
CN102814235A (en) * | 2012-09-04 | 2012-12-12 | 镇江天力变压器有限公司 | Parallel connection high frequency rectifying transformer for static dust extraction |
WO2016038222A1 (en) * | 2014-09-12 | 2016-03-17 | Abb Technology Ag | Traction transformer |
EP3282456B1 (en) * | 2016-08-12 | 2019-04-17 | ABB Schweiz AG | Traction transformer |
KR102448639B1 (en) * | 2020-09-22 | 2022-09-28 | 주식회사 피에스텍 | Rectifier for Generating Very High Voltage DC |
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EP0084912A1 (en) * | 1982-01-22 | 1983-08-03 | Koninklijke Philips Electronics N.V. | High-voltage supply for an X-ray generator |
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- 1995-06-02 US US08/460,072 patent/US5594402A/en not_active Expired - Fee Related
-
1996
- 1996-05-31 CN CN96195318A patent/CN1190486A/en active Pending
- 1996-05-31 JP JP8536692A patent/JPH11506268A/en active Pending
- 1996-05-31 CA CA002222809A patent/CA2222809C/en not_active Expired - Fee Related
- 1996-05-31 WO PCT/US1996/008147 patent/WO1996038849A1/en not_active Application Discontinuation
- 1996-05-31 AU AU59586/96A patent/AU696671B2/en not_active Ceased
- 1996-05-31 EP EP96916846A patent/EP0871966A1/en not_active Withdrawn
- 1996-05-31 US US08/656,162 patent/US5757258A/en not_active Expired - Fee Related
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EP0084912A1 (en) * | 1982-01-22 | 1983-08-03 | Koninklijke Philips Electronics N.V. | High-voltage supply for an X-ray generator |
EP0118269A1 (en) * | 1983-02-28 | 1984-09-12 | CODMAN & SHURTLEFF INC. | Electrical transformer |
JPS59194409A (en) * | 1983-04-19 | 1984-11-05 | Nichicon Capacitor Ltd | High voltage transformer |
EP0464924A1 (en) * | 1990-07-06 | 1992-01-08 | Philips Patentverwaltung GmbH | High voltage transformer, particularly for an X-ray apparatus |
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Also Published As
Publication number | Publication date |
---|---|
CA2222809A1 (en) | 1996-12-05 |
CA2222809C (en) | 2000-09-26 |
AU696671B2 (en) | 1998-09-17 |
US5594402A (en) | 1997-01-14 |
EP0871966A1 (en) | 1998-10-21 |
CN1190486A (en) | 1998-08-12 |
US5757258A (en) | 1998-05-26 |
AU5958696A (en) | 1996-12-18 |
JPH11506268A (en) | 1999-06-02 |
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