High-frequency transformers using solid wire for welding-type power supplies

Patent metadata

Field	Value
Publication number	US-11239026-B2
Application number	US-201816144535-A
Country	US
Kind code	B2
Filing date	Sep 27, 2018
Priority date	Sep 29, 2017
Publication date	Feb 1, 2022
Grant date	Feb 1, 2022

Abstract

High-frequency transformers using solid wire for welding-type power supplies are disclosed. An example welding-type power supply transformer includes: a first coil assembly comprising a first plurality of turns of a first solid wire wrapped around a first bobbin to form a first single-layer primary winding, and a second plurality of turns of a second conductor over the first plurality of turns to form a first single-layer secondary winding; a second coil assembly comprising a third plurality of turns of a second solid wire wrapped around a second bobbin to form a second single-layer primary winding, and a fourth plurality of turns of the second conductor over the third plurality of turns to form a second single-layer secondary winding; and first and second cores disposed at least partially within the first and second bobbins.

First claim

What is claimed is:

1. A welding-type power supply transformer, comprising:
a first coil assembly comprising a first plurality of turns of a first solid wire wrapped around a first bobbin to form a first single-layer primary winding, and a second plurality of turns of a second conductor over the first plurality of turns to form a first single-layer secondary winding, wherein the first solid wire comprises solid magnet wire, extruded aluminum, or rolled aluminum;
a second coil assembly comprising a third plurality of turns of a second solid wire wrapped around a second bobbin to form a second single-layer primary winding, and a fourth plurality of turns of the second conductor over the third plurality of turns to form a second single-layer secondary winding;
first and second cores disposed at least partially within the first and second bobbins, wherein the first ferrite core comprises a first U-core and the second ferrite core comprises a second U-core, the first and second U-cores configured to be inserted into each of the first and second bobbins, and the first and second ferrite cores and the first and second bobbins have obround cross-sections;
a tertiary winding wound around a bridge portion of the first U-core;
a shading ferrite configured to increase a leakage inductance of the tertiary winding; and
polyethylene terephthalate (PET) tubing around at least portions of the first and second secondary windings that are adjacent the first and second primary windings;
wherein the secondary winding comprises extruded aluminum or extruded copper.

2. The transformer as defined in claim 1 , wherein the first solid wire comprises solid magnet wire, extruded aluminum, or rolled aluminum.

3. The transformer as defined in claim 1 , wherein the first single-layer secondary winding is configured to be coupled in series with the second single-layer secondary winding to form a multi-core secondary winding having a center-tap.

4. The transformer as defined in claim 1 , wherein the first single-layer primary winding comprises first insulation, the first single-layer secondary winding comprises second insulation, and the first single-layer secondary winding is wound around the first single-layer primary winding.

5. The transformer as defined in claim 1 , wherein the secondary winding comprises at least one of an obround cross-section, a rectangular cross-section, or a rectangular cross-section having radiused corners.

6. The transformer as defined in claim 1 , further comprising polyethylene terephthalate (PET) tubing around at least portions of the first and second secondary windings that are adjacent the first and second primary windings.

7. The transformer as defined in claim 1 , further comprising polyethylene terephthalate (PET) film wrapped around at least portions of the first and second secondary windings adjacent the first and second primary windings.

8. The transformer as defined in claim 1 , wherein each of the first plurality of turns of the first solid wire comprises a plurality of parallel windings of the first solid wire.

9. The transformer as defined in claim 1 , wherein the first and second bobbins are configured to be mechanically coupled when the first and second cores are positioned within the first and second bobbins.

10. The transformer as defined in claim 1 , wherein the first single-layer primary winding is configured to be coupled in series with the second single-layer primary winding to form a multi-core primary winding.

11. The transformer as defined in claim 1 , wherein the first and second ferrite cores and the first and second bobbins have obround cross-sections.

12. The transformer as defined in claim 1 , wherein the first ferrite core comprises a first U-core and the second ferrite core comprises a second U-core, the first and second U-cores configured to be inserted into each of the first and second bobbins.

13. The transformer as defined in claim 12 , further comprising a tertiary winding wound around a bridge portion of the first U-core.

14. The transformer as defined in claim 13 , further comprising a shading ferrite configured to increase a leakage inductance of the tertiary winding.

Assignees

• Illinois Tool Works

Inventors

• Sigl Dennis Roland

Classifications

• H01F27/2866

  Combination of wires and sheets · CPC title

• H01F27/40

  Structural association with built-in electric component, e.g. fuse · CPC title

• B23K9/1043

  characterised by the electric circuit (B23K9/1012 takes precedence) · CPC title

• H01F38/085 Primary

  Welding transformers · CPC title

• H01F27/2823

  Wires (H01F27/2866 takes precedence) · CPC title