Optimized electromagnetic transformer component design and methods including improved conductivity composite conductor material

Patent metadata

Field	Value
Publication number	US-2016104567-A1
Application number	US-201414511332-A
Country	US
Kind code	A1
Filing date	Oct 10, 2014
Priority date	Oct 10, 2014
Publication date	Apr 14, 2016
Grant date	—

Abstract

Electromagnetic transformer components include a magnetic core and at least two conductors assembled with the core and defining respective windings completing different numbers of turns. The conductors are fabricated from a composite material including carbon nanotubes having an improved conductivity. The transformer is fabricated to have performance parameters that are selected in view of a function of a ratio of conductivity and/or a function of a ratio of effective diameter of the composite conductor material relative to a reference conductor material as conventionally used in a transformer fabrication.

First claim

What is claimed is:

1 . An electromagnetic transformer component comprising:
a magnetic core; and at least two conductors fabricated from a composite conductive material including carbon nanotubes, the at least two conductors respectively shaped to define a primary winding and at least one secondary completing a respectively different number of turns to provide a step up or step down current or voltage output when the at least two conductors are assembled with the magnetic core and connected to electrical circuitry; wherein the at least two conductors respectively have a cross sectional area that is determined relative to at least two reference conductors in a reference transformer component.

2 . The electromagnetic transformer component of claim 1 :
wherein a ratio of an electrical conductivity (β) of the at least two conductors to an electrical conductivity of the at least two reference conductors in the reference electromagnetic component is greater than 1; and wherein the ratio of electrical conductivity (β) defines an upper limit and a lower limit of an effective diameter that corresponds to the cross sectional area of the at least two conductors.

3 . The electromagnetic transformer component of claim 2 :
wherein the transformer component is configured to operate with performance parameters selected from the group of a primary winding volt-second product, magnetizing current, maximum core magnetic field density, total power loss, and a number of turns for the windings when connected to electrical circuitry; and wherein at least one of the performance parameters is within bounded improvement regions defined by at least one function of a ratio of the electrical conductivity (β), an effective diameter ratio (δ) of the at least two conductors relative to the at least two reference conductors, a linear dimension ratio (ξ) of the magnetic core relative to a reference core, and a material constant (γ) of the magnetic material of the core.

4 . The electromagnetic transformer component of claim 3 , wherein a performance value of at least one other performance parameter is selected to be within a respective bounded improvement region defined by the electrical conductivity (β), the effective diameter ratio (δ), the linear dimension ratio (ξ), and the material constant (γ) of the magnetic material of the core.

6 . The electromagnetic transformer component of claim 2 , wherein the ratio of electrical conductivity (β) is within the range of about 1.1 to about 10.

7 . The electromagnetic transformer component of claim 6 , wherein the composite material including carbon nanotubes is an ultra-conductive copper composite material.

8 . The electromagnetic transformer component of claim 3 , wherein the linear dimension ratio (ξ) of the conductor relative to the reference conductor is within a range defined between and including a lower boundary value defined by a function β (−1/8) and an upper boundary value of about 1.

9 . The electromagnetic transformer component of claim 3 , wherein the effective diameter ratio (δ) of the conductor relative to the reference conductor is within a range defined between and including an upper boundary value defined by a function ξ 2 and a lower boundary value of about β (−1/4) .

10 . The electromagnetic transformer component of claim 3 , wherein the effective diameter ratio (δ) of the conductor relative to the reference conductor is within a range defined between and including a lower boundary value defined by a function

(

ξ

4

γ



1
β

)

1

2


(

2
+
γ

)

and an upper boundary value defined by a function ξ 2 .

11 . The electromagnetic transformer component of claim 10 , wherein a value of the number of turns the primary winding and at least one secondary winding, relative to the reference transformer, is defined by a function ξ 2 δ −2 .

12 . The electromagnetic transformer component of claim 10 , wherein a value of the primary winding volt-second product is within a bounded improvement region defined between and including a lower boundary value of 1 and an upper boundary value defined by a function ξ 4 δ −2 .

13 . The electromagnetic transformer component of claim 10 , wherein a value of magnetizing current is within a bounded improvement region defined between and including a lower boundary value defined by a function

ξ

-
2


γ


β


1
2



δ

(

2
+
γ

)

and an upper boundary value defined by a function

β

1
2



δ
2

.

14 . The electromagnetic transformer component of claim 10 , wherein a value of maximum core magnetic field density is within a bounded improvement region defined between and including a lower boundary value defined by a function

(

ξ

-
4


γ



δ

2


(
γ
)

)

1
γ

and an upper limit of 1.

15 . The electromagnetic transformer component of claim 10 , wherein a value of total power loss is within a bounded improvement region defined between and including a lower boundary value defined by a function ξ 3-4γ δ 2γ and an upper boundary value defined by a function ξ 3 .

16 . T

Assignees

• Cooper Technologies Co

Inventors

• Doljack Frank Anthony

Classifications

• H01F41/079

  Measuring electrical characteristics while winding · CPC title

• H01F27/2823 Primary

  Wires (H01F27/2866 takes precedence) · CPC title

• H01F27/24

  Magnetic cores · CPC title

• H01F41/0206

  Manufacturing of magnetic cores by mechanical means (magnetic cores per se H01F27/24) · CPC title

• H01F41/0612

  Electricity · mapped topic