Single litz wire transformers

Patent metadata

Field	Value
Publication number	US-10692646-B2
Application number	US-201715653635-A
Country	US
Kind code	B2
Filing date	Jul 19, 2017
Priority date	Jul 19, 2017
Publication date	Jun 23, 2020
Grant date	Jun 23, 2020

Abstract

Transformers having a plurality of windings from a single Litz wire, as well as systems including such transformers and methods of providing such transformers are disclosed. A transformer includes a core and a single Litz wire having a plurality of individual strands of conductive material. The plurality of individual strands of conductive material are separated into a plurality of groups, each one of the plurality of groups being a winding of the transformer such that the transformer comprises a plurality of windings.

First claim

What is claimed is:

1. A transformer comprising:
a first terminal, a second terminal, a third terminal, and a fourth terminal;
a core; and
a single Litz wire comprising a plurality of individual strands of conductive material,
wherein a first group of one or more strands from the plurality of individual strands is coupled between the first terminal and the second terminal to create a first winding of the transformer and a second group of one or more strands from the plurality of individual strands is coupled between the third terminal and the fourth terminal to create a second winding of the transformer.

2. The transformer of claim 1 , wherein the single Litz wire is wrapped around at least a portion of the core.

3. The transformer of claim 1 , wherein the first group and the second group each comprise an equal number of individual strands relative to one another.

4. The transformer of claim 1 , wherein the first group and the second group each comprise an unequal number of individual strands relative to one another.

5. The transformer of claim 1 , wherein a number of the individual strands within each one of the first group and the second group is based on one or more of an amplitude and a frequency of a current that is passed through the individual strands.

6. The transformer of claim 1 , wherein at least one of a cross sectional shape and a cross sectional size of the single Litz wire is based on an amplitude of a current that is passed through the single Litz wire.

7. The transformer of claim 1 , wherein the transformer exhibits a decreased leakage inductance relative to an alternative transformer comprising a single wire for each winding of the alternative transformer.

8. The transformer of claim 1 , wherein the transformer exhibits less electromagnetic interference relative to an alternative transformer comprising a single wire for each winding of the alternative transformer.

9. The transformer of claim 1 , wherein a coupling between each one of the plurality of windings is increased relative to an alternative transformer comprising a single wire for each winding of the alternative transformer.

10. A transformer comprising:
a first terminal, a second terminal, a third terminal, and a fourth terminal;
a toroidal core; and
a single Litz wire wrapped around at least a portion of the toroidal core, the single Litz wire comprising a plurality of individual strands of conductive material,
wherein a first group of one or more strands from the plurality of individual strands is coupled between the first terminal and the second terminal to create a first winding of the transformer and a second group of one or more strands from the plurality of individual strands is coupled between the third terminal and the fourth terminal to create a second winding of the transformer.

11. The transformer of claim 10 , wherein the first group and the second group each comprise an equal number of individual strands relative to one another.

12. The transformer of claim 10 , wherein the first group and the second group each comprise an unequal number of individual strands relative to one another.

13. The transformer of claim 10 , wherein a number of the individual strands within each one of first group and the second group is based on one or more of an amplitude and a frequency of a current that is passed through the individual strands.

14. The transformer of claim 10 , wherein the toroidal core is formed from a single mass of material.

15. The transformer of claim 10 , wherein the toroidal core is formed from a plurality of layers of material.

16. The transformer of claim 10 , wherein the toroidal core is formed from silicon steel.

17. A system comprising:
a transformer, wherein the transformer comprises:
a first terminal, a second terminal, a third terminal, and a fourth terminal;
a core; and
a single Litz wire wrapped around at least a portion of the toroidal core, the single Litz wire comprising a plurality of individual strands of conductive material,
wherein a first group of one or more strands from the plurality of individual strands is coupled between the first terminal and the second terminal to create a first winding of the transformer and a second group of one or more strands from the plurality of individual strands is coupled between the third terminal and the fourth terminal to create a second winding of the transformer.

18. The system of claim 17 , wherein the first group comprises a first number of individual strands of the single Litz wire and the second group comprises a second number of individual strands of the single Litz wire.

19. The system of claim 18 , wherein the first number is equal to the second number.

20. The system of claim 18 , wherein the first number is not equal to the second number.

Assignees

• Toyota Eng & Mfg North America

Inventors

• Lee Jae Seung
• Shin Jongwon

Classifications

• H01F27/2823 Primary

  Wires (H01F27/2866 takes precedence) · CPC title

• H01B7/30

  with arrangements for reducing conductor losses when carrying alternating current, e.g. due to skin effect · CPC title

• H01F27/324 Primary

  Insulation between coil and core, between different winding sections, around the coil; Other insulation structures · CPC title

• H01F41/08

  Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores · CPC title

• H01F41/07

  Twisting · CPC title