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US 12,476,038 B2Granted
Nested flat wound coils forming windings for transformers and inductors
AssigneeVishay Dale Electronics, Inc.
InventorMatthew J. Foley
Life of this patent
Estimating the term…
Abstract
An electro-magnetic device is provided, including a first winding set of nested windings, and a second winding set of nested windings positioned adjacent to the first winding set. A method of making an electro-magnetic device including a first winding set of nested windings, and a second winding set of nested windings positioned adjacent to the first winding set is also provided.
Claims24
An electro-magnetic device comprising:
- a first winding comprising a wire, the first winding having an opening defining a first diameter;
- a second winding comprising a wire, the second winding having an opening defining a second diameter, the second winding sized to be nested within the opening of the first winding, the first winding and the second winding forming a first winding set having a lowermost surface and an uppermost surface;
- a third winding comprising a wire, the third winding having an opening defining a third diameter;
- a fourth winding comprising a wire, the fourth winding having an opening defining a fourth diameter, the fourth winding sized to be nested within the opening of the third winding, the third winding and the fourth winding forming a second winding set having a lowermost surface and an uppermost surface, wherein the first winding, the second winding, the third winding and the fourth winding are wound around and completely encircle an axis of the electro-magnetic device;
- and
- a support frame comprising a plurality of pins oriented parallel to the axis, wherein an end of each of the first winding, the second winding, the third winding and the fourth winding are connected to a different one of the pins;
- wherein the first winding set is positioned above and adjacent to the second winding set, and wherein the lowermost surface of the first winding set is adjacent to and facing the uppermost surface of the second winding set, and
- wherein at least one of the first winding, the second winding, the third winding, or the fourth winding comprises a flat wire having a rectangular cross-section, and wherein at least one of first winding, the second winding, the third winding, or the fourth winding has an oblong or round cross-section.
5 more elements
A method for manufacturing a transformer with nested flat wound coils, the method comprising:
- forming a first winding comprising a wire, the first winding having an opening defining a first diameter;
- forming a second winding comprising a wire sized to be nested within the opening of the first winding, the second winding having an opening defining a second diameter;
- positioning the second winding within the opening of the first winding to form a first winding set having a thickness and a lowermost surface and an uppermost surface;
- forming a third winding comprising a wire, the third winding having an opening defining a third diameter;
- forming a fourth winding comprising a wire sized to be nested within the opening of the third winding, the fourth winding having an opening defining a fourth diameter;
- positioning the fourth winding within the opening of the third winding to form a second winding set having a thickness and a lowermost surface and an uppermost surface;
- positioning the first winding set above and adjacent to the second winding set, and positioning the lowermost surface of the first winding is adjacent to and facing the uppermost surface of the second winding set, wherein the first winding, the second winding, the third winding and the fourth winding are wound around and completely encircle an axis of the transformer;
- providing a support frame comprising a plurality of pins oriented parallel to the axis;
- and
- connecting an end of each of the first winding, the second winding, the third winding and the fourth winding to a different one of the pins;
- wherein at least one of the first winding, the second winding, the third winding, or the fourth winding comprises a flat wire having a rectangular cross-section, and wherein at least one of the first winding, the second winding, the third winding, or the fourth winding has an oblong or round cross-section.
8 more elements
Dependencies are inferred from the claim text.