CA2569260C - Transformer coil assembly - Google Patents
Transformer coil assembly Download PDFInfo
- Publication number
- CA2569260C CA2569260C CA2569260A CA2569260A CA2569260C CA 2569260 C CA2569260 C CA 2569260C CA 2569260 A CA2569260 A CA 2569260A CA 2569260 A CA2569260 A CA 2569260A CA 2569260 C CA2569260 C CA 2569260C
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- CA
- Canada
- Prior art keywords
- spacers
- fabric
- rows
- coil assembly
- transformer coil
- Prior art date
- Legal status (The legal status 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 status listed.)
- Expired - Fee Related
Links
- 125000006850 spacer group Chemical group 0.000 claims abstract description 107
- 239000004744 fabric Substances 0.000 claims abstract description 52
- 239000004020 conductor Substances 0.000 claims abstract description 41
- 239000011347 resin Substances 0.000 claims abstract description 32
- 229920005989 resin Polymers 0.000 claims abstract description 32
- 239000000835 fiber Substances 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 239000004593 Epoxy Substances 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 3
- 230000003014 reinforcing effect Effects 0.000 claims description 3
- 239000002657 fibrous material Substances 0.000 claims description 2
- 238000004804 winding Methods 0.000 description 5
- 238000005266 casting Methods 0.000 description 4
- 239000004734 Polyphenylene sulfide Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 229920000069 polyphenylene sulfide Polymers 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000003989 dielectric material Substances 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 230000008642 heat stress Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
Classifications
-
- 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
- H01F27/323—Insulation between winding turns, between winding layers
-
- 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
- H01F27/327—Encapsulating or impregnating
-
- 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
- H01F41/122—Insulating between turns or between winding layers
-
- 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
- H01F41/127—Encapsulating or impregnating
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
- Y10T29/49146—Assembling to base an electrical component, e.g., capacitor, etc. with encapsulating, e.g., potting, etc.
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/49155—Manufacturing circuit on or in base
Abstract
A transformer coil assembly (100) includes a first layer (130) having a plurality of fibers interconnected to form a fabric (310) and a plurality of spacers (330). Each spacer is affixed on a first side of the spacer to the fabric and protruding from a first surface of the fabric. A second layer (140) has a conductor (145) in contact with at least one of the plurality of spacers on a second side of each spacer that opposes the first side. The first and second layers are covered by resin (110).
Description
TRANSFORMER COIL ASSEMBLY
BACKGROUND
Transformer coils used in high-voltage and other applications are formed by winding a conductor and casting and curing a thermosetting resin composition around the conductor windings to form a resin body covering the coil. The resin body provides dielectric properties to the transformer coil assembly, as well as holding the conductor windings in place. The resin also provides protection and more uniform thermal properties to the coil assembly. Without some form of support structure for the coil assembly, the resin may develop cracks during casting or during use when the assembly is subjected to external conditions, such as high temperature, high humidity, moisture penetration and the like, or due to internal factors, such as heat generation or stress due to high current flow, electrical fault conditions, and the like.
The resin body is subjected to thermal forces from coil temperatures well above ambient during operation due to I2R losses in the conductors, from eddy currents, from hysteresis losses in the core, and from stray flux impinging the axial ends of the windings. Further, the resin body may be subject to vibratory forces during operation. The resin body should satisfactorily restrain, resist, and withstand all of these forces over long term operation.
SUMMARY
A transformer coil assembly is disclosed that includes a first layer having a plurality of fibers interconnected to form a fabric and a plurality of spacers. Each spacer is affixed on a first side of the spacer to the fabric and protruding from a first surface of the fabric. A second layer has a conductor in contact with at least one of the plurality of spacers on a second side of each spacer that opposes the first side. The first and second layers are covered by resin.
BACKGROUND
Transformer coils used in high-voltage and other applications are formed by winding a conductor and casting and curing a thermosetting resin composition around the conductor windings to form a resin body covering the coil. The resin body provides dielectric properties to the transformer coil assembly, as well as holding the conductor windings in place. The resin also provides protection and more uniform thermal properties to the coil assembly. Without some form of support structure for the coil assembly, the resin may develop cracks during casting or during use when the assembly is subjected to external conditions, such as high temperature, high humidity, moisture penetration and the like, or due to internal factors, such as heat generation or stress due to high current flow, electrical fault conditions, and the like.
The resin body is subjected to thermal forces from coil temperatures well above ambient during operation due to I2R losses in the conductors, from eddy currents, from hysteresis losses in the core, and from stray flux impinging the axial ends of the windings. Further, the resin body may be subject to vibratory forces during operation. The resin body should satisfactorily restrain, resist, and withstand all of these forces over long term operation.
SUMMARY
A transformer coil assembly is disclosed that includes a first layer having a plurality of fibers interconnected to form a fabric and a plurality of spacers. Each spacer is affixed on a first side of the spacer to the fabric and protruding from a first surface of the fabric. A second layer has a conductor in contact with at least one of the plurality of spacers on a second side of each spacer that opposes the first side. The first and second layers are covered by resin.
- 2 -A method of forming a transformer coil assembly is disclosed that includes providing a first fabric layer having a plurality of fibers interconnected and a plurality of protruding spacers affixed to a surface of the fabric. A conductor layer is applied to the first fabric layer in contact with at least one of the plurality of protruding spacers. A resin is applied to cover at least the first fabric layer and the conductor layer.
A transformer coil assembly is disclosed that includes means for establishing a support structure for the transformer coil assembly, the support structure having a first thickness along a first dimension. Spacer means are affixed to the support structure and have a second thickness along the first dimension, the second thickness being greater than the first thickness. The spacer means are formed of a material having a lower compressibility than material used to form the support structure. Conductor means are in contact with the spacer means. Dielectric means cover the support structure means, the spacer means, and the conductor means.
A fibrous material for reinforcing a resin cast transformer coil assembly is disclosed that includes a plurality of fibers interconnected to form a fabric. A plurality of spacers is affixed to the fabric and protrudes from a surface of the fabric. The spacers are arranged in a plurality of rows, where each row is segmented such that superimposing rows onto each other provides an unsegmented row of spacers.
BRIEF DESCRIPTION OF THE DRAWINGS
Objects and advantages will become apparent to those skilled in the art upon reading this description in conjunction with the accompanying drawings, in which like reference numerals have been used to designate like elements, and in which:
FIG. 1 is a perspective view of a transformer coil assembly.
FIG. 2 shows a support structure and spacers.
FIG. 3 shows an area of detail of the transformer coil assembly of FIG. 1.
A transformer coil assembly is disclosed that includes means for establishing a support structure for the transformer coil assembly, the support structure having a first thickness along a first dimension. Spacer means are affixed to the support structure and have a second thickness along the first dimension, the second thickness being greater than the first thickness. The spacer means are formed of a material having a lower compressibility than material used to form the support structure. Conductor means are in contact with the spacer means. Dielectric means cover the support structure means, the spacer means, and the conductor means.
A fibrous material for reinforcing a resin cast transformer coil assembly is disclosed that includes a plurality of fibers interconnected to form a fabric. A plurality of spacers is affixed to the fabric and protrudes from a surface of the fabric. The spacers are arranged in a plurality of rows, where each row is segmented such that superimposing rows onto each other provides an unsegmented row of spacers.
BRIEF DESCRIPTION OF THE DRAWINGS
Objects and advantages will become apparent to those skilled in the art upon reading this description in conjunction with the accompanying drawings, in which like reference numerals have been used to designate like elements, and in which:
FIG. 1 is a perspective view of a transformer coil assembly.
FIG. 2 shows a support structure and spacers.
FIG. 3 shows an area of detail of the transformer coil assembly of FIG. 1.
- 3 -FIG. 4A shows a support structure, spacers, and a conductor.
FIG. 4B illustrates a feature of a spacer pattern of FIG. 4A.
FIGs. 5A-5D show other possible arrangements of the spacers.
FIG. 6 is a flow chart illustrating a method of forming a transformer coil assembly.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of a transformer coil assembly 100 according to an exemplary embodiment. The transformer coil assembly 100 includes a first layer 130 and a second layer 140. Referring also to FIG. 3, which details an area of the transformer coil assembly 100 of FIG. 1, a first layer 130 of the transformer coil assembly 100 includes means for establishing a support structure 310.
The means for establishing a support structure 310 can include multiple fibers interconnected to form a fabric. The fabric can include glass fibers and can include electrical grade glass. The fabric can include any of a variety of fibers that are known in this art to be suitable for transformer cast applications, such as polyphenylene sulfide (PPS), polyamides (nylon), polyvinyl chloride (PVC), flouropolymers (PTFE), and the like.
The first layer 130 of the transformer coil assembly 100 also includes spacer means 330, affixed to the support structure means 310. The spacer means 330 can include multiple spacers and is preferably formed of a less compressive material than fabric, such as resin or epoxy. The spacer means 330 are affixed to a surface of the support structure means 310.
Here, the term "affixed" means that the spacers can be secured adjacent to a surface of the support structure means 310, by adhesives or other known means, or can be partially embedded in the support structure means 310.
The spacer means 330 protrude from the support structure means 310 by a distance, i.e., height, 335. It should be appreciated that although the spacer means 330 are shown affixed to only one surface of the support structure
FIG. 4B illustrates a feature of a spacer pattern of FIG. 4A.
FIGs. 5A-5D show other possible arrangements of the spacers.
FIG. 6 is a flow chart illustrating a method of forming a transformer coil assembly.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of a transformer coil assembly 100 according to an exemplary embodiment. The transformer coil assembly 100 includes a first layer 130 and a second layer 140. Referring also to FIG. 3, which details an area of the transformer coil assembly 100 of FIG. 1, a first layer 130 of the transformer coil assembly 100 includes means for establishing a support structure 310.
The means for establishing a support structure 310 can include multiple fibers interconnected to form a fabric. The fabric can include glass fibers and can include electrical grade glass. The fabric can include any of a variety of fibers that are known in this art to be suitable for transformer cast applications, such as polyphenylene sulfide (PPS), polyamides (nylon), polyvinyl chloride (PVC), flouropolymers (PTFE), and the like.
The first layer 130 of the transformer coil assembly 100 also includes spacer means 330, affixed to the support structure means 310. The spacer means 330 can include multiple spacers and is preferably formed of a less compressive material than fabric, such as resin or epoxy. The spacer means 330 are affixed to a surface of the support structure means 310.
Here, the term "affixed" means that the spacers can be secured adjacent to a surface of the support structure means 310, by adhesives or other known means, or can be partially embedded in the support structure means 310.
The spacer means 330 protrude from the support structure means 310 by a distance, i.e., height, 335. It should be appreciated that although the spacer means 330 are shown affixed to only one surface of the support structure
- 4 -means 310, the spacer means 330 can also be attached to both opposing surfaces of the support structure means 310.
The second layer 140 includes a conductor means 145 in contact with at least one of the spacers of the spacer means 330 on a second side 332 of each spacer that opposes the first side 331. The conductor means 145 can be a single conductor that is wound continuously to form a single transformer coil winding, or can be multiple conductors, depending on the type of transformer coil assembly 100. The conductor means 145 can include tabs 168 for accessing the conductor means 145 by other electrical components outside the transformer coil assembly 100.
The transformer coil assembly 100 includes a dielectric means for covering the support structure means 310, the spacer means 330, and the conductor means 145. The dielectric means can be a resin body 110 .
covering the layers of the transformer coil assembly 100. Although the dielectric means will be described hereinafter as a resin body 110, or simply resin 110, one of skill in this art will recognize that a number of dielectric materials may be used that are suitable for use in a transformer cast. The thickness of the resin body should be uniform to provide dielectric properties that are uniform throughout the transformer coil assembly. Here, the term uniform means substantially the same throughout with some tolerance. A
dielectric with favorable properties will resist breakdown under high voltages, does not itself draw appreciable power from the circuit, is physically stable, and has characteristics that do not vary much over a fairly wide temperature range.
The transformer coil assembly 100 can optionally include a third layer 150 having support structure means 315 and spacer means 335. The third layer 150 can be made of the same materials as the first layer, although this is not a requirement. When the optional third layer 150 is employed, the dielectric means, such as a resin body 110, can cover the first, second, and third layers 130, 140, 150, providing an overall thickness 160.
The second layer 140 includes a conductor means 145 in contact with at least one of the spacers of the spacer means 330 on a second side 332 of each spacer that opposes the first side 331. The conductor means 145 can be a single conductor that is wound continuously to form a single transformer coil winding, or can be multiple conductors, depending on the type of transformer coil assembly 100. The conductor means 145 can include tabs 168 for accessing the conductor means 145 by other electrical components outside the transformer coil assembly 100.
The transformer coil assembly 100 includes a dielectric means for covering the support structure means 310, the spacer means 330, and the conductor means 145. The dielectric means can be a resin body 110 .
covering the layers of the transformer coil assembly 100. Although the dielectric means will be described hereinafter as a resin body 110, or simply resin 110, one of skill in this art will recognize that a number of dielectric materials may be used that are suitable for use in a transformer cast. The thickness of the resin body should be uniform to provide dielectric properties that are uniform throughout the transformer coil assembly. Here, the term uniform means substantially the same throughout with some tolerance. A
dielectric with favorable properties will resist breakdown under high voltages, does not itself draw appreciable power from the circuit, is physically stable, and has characteristics that do not vary much over a fairly wide temperature range.
The transformer coil assembly 100 can optionally include a third layer 150 having support structure means 315 and spacer means 335. The third layer 150 can be made of the same materials as the first layer, although this is not a requirement. When the optional third layer 150 is employed, the dielectric means, such as a resin body 110, can cover the first, second, and third layers 130, 140, 150, providing an overall thickness 160.
- 5 -The means for establishing support structure 310 provides reinforcing support to the resin body 110 to prevent the development of cracks during casting or during use when the assembly is subjected to external conditions, such as high temperature, high humidity, moisture penetration and the like, or due to internal factors, such as high coil temperatures or vibratory forces during operation.
The spacer means 330 protrude from the support structure means 310 by a distance 335. The protrusion of the spacer means 330 creates a space 320 between conductor means 145 and the support structure means 310, where the resin 110 can more easily flow during the casting process.
That is, without the spacers, the resin would have to "wick" into the support structure, which takes additional time and may produce uneven dispersion of the resin 110. Uneven dispersion produces a resin body 110 that does not have uniform dielectric properties. The spacer means 330 provides a more even resin body 110 having more uniform dielectric properties than using, for example, a support structure 310 only.
Moreover, the height 335 of the spacer means 330 can be selected to provide a desired overall thickness 120 of the first layer 130 using less support structure means 310, such as fabric. That is, to achieve the same thickness 120 of the first layer 130, and therefore the same dielectric properties, without the spacer means 330, many layers of fabric would typically be required. The layers of fabric would not only cause uneven = dispersing of the resin 110, as described above, but would be subject to compression by the conductor means 145 as the conductor means 145 is applied, e.g., wound, over the fabric layers. Compression is typically uneven and results in a non-uniform thickness of the first layer, causing non-uniform dielectric properties. The spacer means 330 therefore preferably is less = compressive, i.e., is less subject to changes in volume when a force is applied, than the support structure means 310. For example, epoxy spacers are less compressive than layers of electrical grade glass.
The spacer means 330 protrude from the support structure means 310 by a distance 335. The protrusion of the spacer means 330 creates a space 320 between conductor means 145 and the support structure means 310, where the resin 110 can more easily flow during the casting process.
That is, without the spacers, the resin would have to "wick" into the support structure, which takes additional time and may produce uneven dispersion of the resin 110. Uneven dispersion produces a resin body 110 that does not have uniform dielectric properties. The spacer means 330 provides a more even resin body 110 having more uniform dielectric properties than using, for example, a support structure 310 only.
Moreover, the height 335 of the spacer means 330 can be selected to provide a desired overall thickness 120 of the first layer 130 using less support structure means 310, such as fabric. That is, to achieve the same thickness 120 of the first layer 130, and therefore the same dielectric properties, without the spacer means 330, many layers of fabric would typically be required. The layers of fabric would not only cause uneven = dispersing of the resin 110, as described above, but would be subject to compression by the conductor means 145 as the conductor means 145 is applied, e.g., wound, over the fabric layers. Compression is typically uneven and results in a non-uniform thickness of the first layer, causing non-uniform dielectric properties. The spacer means 330 therefore preferably is less = compressive, i.e., is less subject to changes in volume when a force is applied, than the support structure means 310. For example, epoxy spacers are less compressive than layers of electrical grade glass.
- 6 -FIG. 2 shows a support structure 210 with spacers 230. The support structure 210 includes a plurality of fibers 220 interconnected to form a fabric. Although a grid-like pattern is illustrated, any pattern can be used.
Multiple spacers 230 are affixed to the fabric 210 and protruding from a surface of the fabric 210.
The spacers 230 can be arranged in a plurality of rows 240A, 240B.
The rows 240A, 240B can be segmented as shown. FIG. 2 shows the spacers 230 arranged in one of many patterns that can be used. FIGs. 5A-5D show other possible patterns of the spacers that can be used.
FIG. 4A shows a support structure, spacers, and a conductor. The spacers 230 are shown arranged in a plurality of rows 240A, 240B. A
conductor 430 has a first end 410 and a second end 430 and is continuous such that segment ends 420A and 420B are connected, i.e., represent the same point, and so on. The spacers 230 are shown arranged in a pattern so that the conductor 430 contacts only the spacers 230, and contacts a spacer 230 at least every two rows. This pattern provides support for the conductor 430 every two rows.
FIG. 4B illustrates this feature of the spacer pattern of FIG. 4A. The superimposition of row 240A onto 2406 provides an unsegmented row of spacers. Here, the term "unsegmented" is meant to include both a contiguous row of adjacent spacers and a row of overlapping spacers. This feature helps define the pattern of FIG. 4A. Likewise, as can be appreciated, in the pattern of FIG. 5A, the superimposition of three rows onto each other provides an unsegmented row of spacers. In FIG. 5B, the superimposition of four rows onto each other provides an unsegmented row of spacers. In FIGs. 5A and 5B, the respective pattern provides support for the conductor 430 every three rows and every four rows. This can be expanded to any number of rows.
As can be appreciated from FIG. 5C, the rows need not be segmented, although it is preferable as discussed below. Moreover, as can be appreciated from FIG. 5D, the spacers can be of varying sizes and
Multiple spacers 230 are affixed to the fabric 210 and protruding from a surface of the fabric 210.
The spacers 230 can be arranged in a plurality of rows 240A, 240B.
The rows 240A, 240B can be segmented as shown. FIG. 2 shows the spacers 230 arranged in one of many patterns that can be used. FIGs. 5A-5D show other possible patterns of the spacers that can be used.
FIG. 4A shows a support structure, spacers, and a conductor. The spacers 230 are shown arranged in a plurality of rows 240A, 240B. A
conductor 430 has a first end 410 and a second end 430 and is continuous such that segment ends 420A and 420B are connected, i.e., represent the same point, and so on. The spacers 230 are shown arranged in a pattern so that the conductor 430 contacts only the spacers 230, and contacts a spacer 230 at least every two rows. This pattern provides support for the conductor 430 every two rows.
FIG. 4B illustrates this feature of the spacer pattern of FIG. 4A. The superimposition of row 240A onto 2406 provides an unsegmented row of spacers. Here, the term "unsegmented" is meant to include both a contiguous row of adjacent spacers and a row of overlapping spacers. This feature helps define the pattern of FIG. 4A. Likewise, as can be appreciated, in the pattern of FIG. 5A, the superimposition of three rows onto each other provides an unsegmented row of spacers. In FIG. 5B, the superimposition of four rows onto each other provides an unsegmented row of spacers. In FIGs. 5A and 5B, the respective pattern provides support for the conductor 430 every three rows and every four rows. This can be expanded to any number of rows.
As can be appreciated from FIG. 5C, the rows need not be segmented, although it is preferable as discussed below. Moreover, as can be appreciated from FIG. 5D, the spacers can be of varying sizes and
- 7 -patterns, and need not be in rows. The spacer pattern can be purely random if desired.
It is, however, preferable to use segmented rows of spacers. The segmenting allows better flow of the resin around the spacers. In addition, longer spacers are more likely to conduct electricity from one area of the conductor to another, or create a voltage potential between spacers.
FIG. 6 is a flow chart illustrating a method of forming a transformer coil assembly. A method of forming a transformer coil assembly includes providing a first fabric layer having a plurality of fibers interconnected and a plurality of protruding spacers affixed to a surface of the fabric (600). A
conductor layer is applied to the first fabric layer in contact with at least one of the plurality of protruding spacers (610). A resin is applied to cover at least the first fabric layer and the conductor layer (620).
It will be appreciated by those of ordinary skill in the art that the invention can be embodied in various specific forms without departing from its essential characteristics. The disclosed embodiments are considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced thereby.
It should be emphasized that the terms "comprises", "comprising", "includes" and "including" when used in this description and claims, are taken to specify the presence of stated features, steps, or components, but the use of these terms does not preclude the presence or addition of one or more other features, steps, components, or groups thereof.
It is, however, preferable to use segmented rows of spacers. The segmenting allows better flow of the resin around the spacers. In addition, longer spacers are more likely to conduct electricity from one area of the conductor to another, or create a voltage potential between spacers.
FIG. 6 is a flow chart illustrating a method of forming a transformer coil assembly. A method of forming a transformer coil assembly includes providing a first fabric layer having a plurality of fibers interconnected and a plurality of protruding spacers affixed to a surface of the fabric (600). A
conductor layer is applied to the first fabric layer in contact with at least one of the plurality of protruding spacers (610). A resin is applied to cover at least the first fabric layer and the conductor layer (620).
It will be appreciated by those of ordinary skill in the art that the invention can be embodied in various specific forms without departing from its essential characteristics. The disclosed embodiments are considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced thereby.
It should be emphasized that the terms "comprises", "comprising", "includes" and "including" when used in this description and claims, are taken to specify the presence of stated features, steps, or components, but the use of these terms does not preclude the presence or addition of one or more other features, steps, components, or groups thereof.
Claims (19)
1. A transformer coil assembly, comprising:
a first layer having a plurality of fibers interconnected to form a fabric and a plurality of rows of spaced-apart spacers, each spacer affixed on a first side of the spacer to the fabric and protruding from a first surface of the fabric;
a second layer having a conductor in contact with at least one of the spacers in each of the plurality of rows of spacers on a second side of each spacer that opposes the first side; and a resin body covering the first and second layers.
a first layer having a plurality of fibers interconnected to form a fabric and a plurality of rows of spaced-apart spacers, each spacer affixed on a first side of the spacer to the fabric and protruding from a first surface of the fabric;
a second layer having a conductor in contact with at least one of the spacers in each of the plurality of rows of spacers on a second side of each spacer that opposes the first side; and a resin body covering the first and second layers.
2. The transformer coil assembly of claim 1, comprising:
a third layer having a plurality of fibers interconnected to form a fabric and a plurality of spacers, each spacer affixed on a first side of the spacer to the fabric and protruding from a surface of the fabric to contact the conductor on a second side of each spacer, wherein the resin body covers the first, second, and third layers.
a third layer having a plurality of fibers interconnected to form a fabric and a plurality of spacers, each spacer affixed on a first side of the spacer to the fabric and protruding from a surface of the fabric to contact the conductor on a second side of each spacer, wherein the resin body covers the first, second, and third layers.
3. The transformer coil assembly of claim 1 or 2, wherein the plurality of spacers comprises spacers affixed to, and protruding from, a second surface of the fabric, opposing the first surface.
4. The transformer coil assembly of any one of claims 1 to 3, wherein an average distance along a surface of the fabric between adjacent spacers is greater than an average distance along a surface of the fabric between adjacent interconnected fibers.
5. The transformer coil assembly of any one of claims 1 to 4, wherein each of the plurality of rows of spacers are segmented.
6. The transformer coil assembly of any one of claims 1 to 5, wherein each row of the plurality of rows of spacers is segmented such that superimposition of rows onto each other provides an unsegmented row of spacers.
7. The transformer coil assembly of any one of claims 1 to 6, wherein the plurality of interconnected fibers comprises glass fibers.
8. The transformer coil assembly of claim 7, wherein the glass fibers comprise electrical grade glass.
9. The transformer coil assembly of any one of claims 1 to 8, wherein the spacers comprise resin.
10. The transformer coil assembly of any one of claims 1 to 8, wherein the spacers comprise epoxy.
11. The transformer coil assembly of any one of claims 1 to 10, wherein the spacers are partially embedded into the fabric.
12. A method of forming a transformer coil assembly, comprising:
providing a first fabric layer having a plurality of fibers interconnected and a first plurality of rows of spaced-apart protruding spacers affixed to a surface of the fabric;
applying, to the first fabric layer, a conductor layer in contact with at least one spacer of each of the rows of protruding spacers; and applying resin to cover at least the first fabric layer and the conductor layer; and wherein each of the spacers of the plurality of rows of spacers are separated by spaces.
providing a first fabric layer having a plurality of fibers interconnected and a first plurality of rows of spaced-apart protruding spacers affixed to a surface of the fabric;
applying, to the first fabric layer, a conductor layer in contact with at least one spacer of each of the rows of protruding spacers; and applying resin to cover at least the first fabric layer and the conductor layer; and wherein each of the spacers of the plurality of rows of spacers are separated by spaces.
13. The method of claim 12, comprising:
applying, to the conductor layer, a second fabric layer having a plurality of fibers interconnected and a second plurality of rows of spaced-apart protruding spacers affixed to a surface of the fabric; and applying sufficient resin to cover the first fabric layer, the conductor layer, and the second fabric layer.
applying, to the conductor layer, a second fabric layer having a plurality of fibers interconnected and a second plurality of rows of spaced-apart protruding spacers affixed to a surface of the fabric; and applying sufficient resin to cover the first fabric layer, the conductor layer, and the second fabric layer.
14. The method of claim 12, wherein applying the conductor layer comprises applying the conductor to contact, of the first fabric layer, only ones of the first plurality of rows of protruding spacers.
15. The method of claim 13, wherein applying a second fabric layer comprises applying the second fabric layer so that only ones of the second plurality of rows of protruding spacers contact the conductor.
16. A transformer coil assembly, comprising:
means for establishing a support structure for the transformer coil assembly, the support structure having a first thickness along a first dimension;
a plurality of rows of spaced-apart spacer means, affixed to the support structure and having a second thickness along the first dimension, the second thickness being greater than the first thickness, the plurality of rows of spaced-apart spacer means being formed of a material having a lower compressibility than a material used to form the support structure;
conductor means in contact with the plurality of rows of spacer means;
and dielectric means for covering the support structure means, the plurality of rows of spacer means, and the conductor means.
means for establishing a support structure for the transformer coil assembly, the support structure having a first thickness along a first dimension;
a plurality of rows of spaced-apart spacer means, affixed to the support structure and having a second thickness along the first dimension, the second thickness being greater than the first thickness, the plurality of rows of spaced-apart spacer means being formed of a material having a lower compressibility than a material used to form the support structure;
conductor means in contact with the plurality of rows of spacer means;
and dielectric means for covering the support structure means, the plurality of rows of spacer means, and the conductor means.
17. The transformer coil assembly of claim 16, wherein the support structure means comprises:
a first and second support structure, each having first and second respective spacer means affixed thereto, and the conductor means is positioned between the first and second support structure in contact with both the first and second respective spacer means.
a first and second support structure, each having first and second respective spacer means affixed thereto, and the conductor means is positioned between the first and second support structure in contact with both the first and second respective spacer means.
18. The transformer coil assembly of claim 16 or 17, wherein the spacer means comprises:
a plurality of spacers arranged in a plurality of segmented rows, and each row is segmented such that superimposition of rows onto each other provides an unsegmented row of spacers.
a plurality of spacers arranged in a plurality of segmented rows, and each row is segmented such that superimposition of rows onto each other provides an unsegmented row of spacers.
19. A fibrous material for reinforcing a resin cast transformer coil assembly, the material comprising:
a plurality of fibers interconnected to form a fabric; and a plurality of spacers affixed to the fabric and protruding from a surface of the fabric, wherein the spacers are arranged in a plurality of rows, each row being segmented such that superimposition of rows onto each other provides an unsegmented row of spacers.
a plurality of fibers interconnected to form a fabric; and a plurality of spacers affixed to the fabric and protruding from a surface of the fabric, wherein the spacers are arranged in a plurality of rows, each row being segmented such that superimposition of rows onto each other provides an unsegmented row of spacers.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/858,039 | 2004-06-01 | ||
US10/858,039 US7688170B2 (en) | 2004-06-01 | 2004-06-01 | Transformer coil assembly |
PCT/US2005/018801 WO2005119710A2 (en) | 2004-06-01 | 2005-05-27 | Transformer coil assembly |
Publications (2)
Publication Number | Publication Date |
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CA2569260A1 CA2569260A1 (en) | 2005-12-15 |
CA2569260C true CA2569260C (en) | 2014-03-11 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA2569260A Expired - Fee Related CA2569260C (en) | 2004-06-01 | 2005-05-27 | Transformer coil assembly |
Country Status (6)
Country | Link |
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US (2) | US7688170B2 (en) |
EP (1) | EP1774546A4 (en) |
CN (1) | CN1973343B (en) |
BR (1) | BRPI0511720B1 (en) |
CA (1) | CA2569260C (en) |
WO (1) | WO2005119710A2 (en) |
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US5485370A (en) | 1988-05-05 | 1996-01-16 | Transaction Technology, Inc. | Home services delivery system with intelligent terminal emulator |
US7688170B2 (en) * | 2004-06-01 | 2010-03-30 | Abb Technology Ag | Transformer coil assembly |
US7719397B2 (en) * | 2006-07-27 | 2010-05-18 | Abb Technology Ag | Disc wound transformer with improved cooling and impulse voltage distribution |
ATE522916T1 (en) * | 2008-05-13 | 2011-09-15 | Abb Technology Ag | DRY TRANSFORMER |
US8456266B2 (en) | 2009-06-22 | 2013-06-04 | Engineered Products Of Virginia, Llc | Transformer coil assembly |
DE112009005222B4 (en) * | 2009-09-11 | 2022-12-29 | Hitachi Energy Switzerland Ag | Transformer with a heat pipe and method of manufacturing a transformer |
US9640314B2 (en) | 2010-04-07 | 2017-05-02 | Abb Schweiz Ag | Outdoor dry-type transformer |
US8484831B2 (en) | 2010-07-27 | 2013-07-16 | Honeywell International Inc. | Methods of forming insulated wires and hermetically-sealed packages for use in electromagnetic devices |
US9257229B2 (en) | 2011-09-13 | 2016-02-09 | Abb Technology Ag | Cast split low voltage coil with integrated cooling duct placement after winding process |
EP3007189B1 (en) * | 2014-10-07 | 2020-04-15 | ABB Power Grids Switzerland AG | Vehicle transformer |
WO2017040303A1 (en) * | 2015-08-29 | 2017-03-09 | Abb Schweiz Ag | Transformer, coil assembly and spacer |
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Publication number | Priority date | Publication date | Assignee | Title |
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US1495823A (en) * | 1921-01-14 | 1924-05-27 | Acme Wire Company | Electrical coil and method of making the same |
US1495832A (en) * | 1923-04-21 | 1924-05-27 | Hazel R Aiken | Artificial bait |
US2942217A (en) * | 1957-08-30 | 1960-06-21 | Westinghouse Electric Corp | Electrical coil |
US3234493A (en) * | 1963-06-17 | 1966-02-08 | Mc Graw Edison Co | Distribution transformer having a molded insulative casing and oil dielectric |
US3711807A (en) * | 1970-07-12 | 1973-01-16 | Northern Ind & Mfg Inc | A molded coil |
US3678428A (en) * | 1971-05-17 | 1972-07-18 | Westinghouse Electric Corp | Interwinding shield for power transformers |
US3789337A (en) * | 1971-12-17 | 1974-01-29 | Westinghouse Electric Corp | Insulation structure for electrical apparatus |
US3934332A (en) * | 1974-11-26 | 1976-01-27 | Westinghouse Electric Corporation | Method of making electrical coils having improved strength and oil permeability |
US3946350A (en) * | 1975-03-26 | 1976-03-23 | Katsuichi Goto | Coil assembly for bobbin wound transformer |
US4264887A (en) * | 1978-11-24 | 1981-04-28 | Wehr Corporation | Electro-lifting magnet |
JPS5752107A (en) * | 1980-09-16 | 1982-03-27 | Toshiba Corp | Resin-immersed molded coil |
IT1144387B (en) | 1981-07-16 | 1986-10-29 | Indesit | INSULATION SYSTEM FOR A REFRIGERATOR |
JPS5842213A (en) * | 1981-09-04 | 1983-03-11 | Mitsubishi Electric Corp | Manufacture of synthetic resin molded coil |
NL8802882A (en) * | 1988-11-22 | 1990-06-18 | Smit Transformatoren Bv | TRANSFORMER WINDING EXPLODED WITH AXIAL CHANNELS DISC WINDING. |
US5588201A (en) * | 1991-03-21 | 1996-12-31 | Siemens Aktiengesellschaft | Process for producing a cast resin coil |
TW299064U (en) * | 1995-01-23 | 1997-02-21 | Hitachi Ltd | Resin molded transformer |
US6160464A (en) * | 1998-02-06 | 2000-12-12 | Dynapower Corporation | Solid cast resin coil for high voltage transformer, high voltage transformer using same, and method of producing same |
US7688170B2 (en) | 2004-06-01 | 2010-03-30 | Abb Technology Ag | Transformer coil assembly |
-
2004
- 2004-06-01 US US10/858,039 patent/US7688170B2/en not_active Expired - Fee Related
-
2005
- 2005-05-27 BR BRPI0511720A patent/BRPI0511720B1/en not_active IP Right Cessation
- 2005-05-27 WO PCT/US2005/018801 patent/WO2005119710A2/en active Application Filing
- 2005-05-27 CN CN2005800202731A patent/CN1973343B/en not_active Expired - Fee Related
- 2005-05-27 CA CA2569260A patent/CA2569260C/en not_active Expired - Fee Related
- 2005-05-27 EP EP05771693A patent/EP1774546A4/en not_active Withdrawn
-
2007
- 2007-05-24 US US11/752,986 patent/US7905009B2/en not_active Expired - Fee Related
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CA2569260A1 (en) | 2005-12-15 |
EP1774546A4 (en) | 2012-11-28 |
CN1973343B (en) | 2011-06-15 |
BRPI0511720A (en) | 2008-01-08 |
WO2005119710A3 (en) | 2006-08-03 |
WO2005119710A2 (en) | 2005-12-15 |
BRPI0511720B1 (en) | 2017-03-21 |
EP1774546A2 (en) | 2007-04-18 |
US20050275496A1 (en) | 2005-12-15 |
US7688170B2 (en) | 2010-03-30 |
US20070220738A1 (en) | 2007-09-27 |
US7905009B2 (en) | 2011-03-15 |
CN1973343A (en) | 2007-05-30 |
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