# US 2021/0241964 A1 · Delta circuit embedded contactors of a harmonic filter apparatus and method of use thereof

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- Number: US 2021/0241964 A1
- Document ID: US20210241964A1
- Status: Published application
- Kind: A1
- Application number: 17/235,375
- Filed: 2021-04-20
- Published: 2021-08-05
- Earliest claimed: 2007-04-05
- Assignees: CTM Magnetics, Inc.
- Inventors: Hans Wennerstrom; Corey Jones; Grant A. MacLennan
- Web page: https://patentgrep.com/patent/US20210241964A1

## CPC

- H01F 27/2895: {Windings disposed upon ring cores}
- H02M 5/458: using semiconductor devices only
- H01F 27/085: {Cooling by ambient air}
- H01F 27/10: Liquid cooling
- H01F 27/255: made from particles (H01F27/26 takes precedence)
- H01F 27/266: {Fastening or mounting the core on casing or support (on coil H01F27/30)}
- H01F 27/2823: {Wires (H01F27/2866 takes precedence)}
- H01F 27/2876: {Cooling (cooling transformers and inductances in general H01F27/08)}
- H01F 27/306: {Fastening or mounting coils or windings on core, casing or other support}
- H01F 27/324: {Insulation between coil and core, between different winding sections, around the coil; Other insulation structures}
- H01F 27/385: {for reducing harmonics}
- H01F 27/40: Structural association with built-in electric component, e.g. fuse
- H01F 37/00: Fixed inductances not covered by group H01F17/00
- H02M 1/126: {using passive filters}
- H01F 1/24: the particles being insulated
- H01F 27/08: Cooling (heat-transfer elements F28F); Ventilating (structural details of casings H01F27/02)
- H01G 4/38: Multiple capacitors, i.e. structural combinations of fixed capacitors
- H01G 4/40: Structural combinations of fixed capacitors with other electric elements, the structure mainly consisting of a capacitor, e.g. RC combinations
- H02M 1/123: {Suppression of common mode voltage or current}
- Y02B 70/10: Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes
- Y02P 80/20: using renewable energy
- Y02T 10/70: Energy storage systems for electromobility, e.g. batteries
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

The invention comprises a harmonic filter apparatus and method of use thereof, the harmonic filter including a delta circuit comprising: (1) a first leg connecting a first apex to a second apex of the delta circuit; a second leg connecting the second apex to a third apex of the delta circuit; and a third leg connecting the third apex to the first apex and (2) a first electrical contactor and a second electrical contactor positioned within at least two of: the first leg, the second leg; and the third leg. Optionally and preferably, each apex of the delta circuit is connected to individual phases of three phase power via respective inductor—coupled inductor pairs, where the harmonic filter magnetically isolates individual phases of the three phase power.

## Claims

### Claim 1

An apparatus, comprising:
a harmonic filter comprising:
a delta circuit comprising:
a first leg connecting a first apex to a second apex of said delta circuit, a second leg connecting said second apex to a third apex of said delta circuit, and a third leg connecting said third apex to said first apex; and
a first electrical contactor and a second electrical contactor positioned within at least two of: said first leg, said second leg; and
said third leg.

### Claim 2 (depends on 1)

The apparatus of claim 1, said harmonic filter further comprising:
a first inductor—coupled inductor pair connected to said first apex;
a second inductor—coupled inductor pair connected to said second apex; and
a third inductor—coupled inductor pair connected to said third apex,
said harmonic filter magnetically isolating three phase power.

### Claim 3 (depends on 1)

The apparatus of claim 1, said first contactor further comprising:
a rating of 100±50 amperes, said harmonic filter configured to filter current of greater than 450 amperes.

### Claim 4 (depends on 2)

The apparatus of claim 2, said harmonic filter further comprising:
at least one inductor comprising:
a core; and
a fabricated winding comprising a plurality of turns, at least a first turn of said plurality of turns comprising: a first sub-section and a second sub-section electrically connected in a manufacturing step to said first sub-section with a first electrical non-direct wire connection.

### Claim 5 (depends on 1)

The apparatus of claim 1, further comprising:
first circuitry on said first leg matching second circuitry on said second leg, said first circuitry comprising at least two contactors electrically wired in parallel.

### Claim 6 (depends on 5)

The apparatus of claim 5, each of said at least two contactors further comprising:
a rating of 50±40 amperes, said harmonic filter configured to filter current of greater than one hundred amperes.

### Claim 7 (depends on 1)

The apparatus of claim 1, further comprising:
at least one capacitor in each leg of said delta circuit, a first capacitor of said at least one capacitor constructed with metallized film.

### Claim 8 (depends on 1)

The apparatus of claim 1, further comprising:
said first electrical contactor and a third electrical contactor wired in parallel within said first leg of said delta circuit.

### Claim 9 (depends on 8)

The apparatus of claim 8, said first leg further comprising:
at least four contactors, each of said contactors comprising a rating of 5 to 50 amperes.

### Claim 10 (depends on 8)

The apparatus of claim 8, further comprising:
a first capacitor and a second capacitor wired in parallel within said first leg of said delta circuit.

### Claim 11 (depends on 1)

The apparatus of claim 1, said harmonic filter further comprising:
a first inductor and a coupled inductor electrically linked to said delta circuit via said first apex;
at least one of said first inductor and said coupled inductor comprising: an inductor core comprising:
a plurality of coated magnetic particles, each of a majority of said coated magnetic particles comprising:
a first set of alternating magnetic layers, wherein said magnetic layers comprise at least one alloy; and
a second set of alternating substantially non-magnetic layers, said coated magnetic particles about evenly distributed in at least a portion of said inductor core.

### Claim 12 (depends on 11)

The apparatus of claim 11, further comprising:
a high frequency inverter comprising a switching device.

### Claim 13

A method for processing three phase electrical power, comprising the steps of:
filtering the three phase electrical power with a harmonic filter comprising:
a delta circuit comprising:
a first leg connecting a first apex of said delta circuit to a second apex of said delta circuit; a second leg connecting said second apex to a third apex of said delta circuit; and a third leg connecting said third apex to said first apex; and
alternatingly connecting/disconnecting said delta circuit from the three phase electrical power with a first electrical contactor and a second electrical contactor positioned within at least two of: said first leg, said second leg; and said third leg of said delta circuit.

### Claim 14 (depends on 13)

The method of claim 13, further comprising the steps of:
magnetically isolating individual phases of the three phase electrical power with said harmonic filter, said harmonic filter further comprising:
a first inductor—coupled inductor pair connected to a first phase of the three phase electrical power and a first apex of said delta circuit;
a second inductor—coupled inductor pair connected to a second phase of the three phase electrical power and a second apex of said delta circuit; and
a third inductor—coupled inductor pair connected to a third phase of the three phase electrical power and a third apex of the delta circuit.

### Claim 15 (depends on 14)

The method of claim 14, further comprising the steps of:
mounting said first inductor—coupled inductor pair, said second inductor—coupled inductor pair, and said third inductor—coupled inductor pair on a mounting rail;
longitudinally enclosing in a housing said first inductor—coupled inductor pair, said second inductor—coupled inductor pair, and said third inductor—coupled pair, said housing comprising a first elongated section joined to a second elongated section of said housing; and
said step of enclosing, forming through a longitudinal length of said enclosure at least one aperture through which a connector to at least said first inductor—coupled inductor pair passes.

### Claim 16 (depends on 14)

The method of claim 14, further comprising the step of:
forming a first inductor, of said first inductor-coupled inductor pair of said harmonic filter, by joining: (1) a first sub-section of a first turn of a winding and (2) a second sub-section of said first turn of said winding with a new electrical connection, wherein said first turn comprises a turn of a plurality of turns in a fabricated winding about a core of said first inductor.

### Claim 17 (depends on 14)

The method of claim 14, further comprising the step of:
winding a first inductor core, of said first inductor—coupled inductor pair, with at least four electrical turns mechanically affixed to one another in series during manufacture.

### Claim 18 (depends on 14)

The method of claim 14, further comprising the steps of:
fastening a first inductor, of said first inductor-coupled inductor pair of said harmonic filter, to a mounting plate with a set of mechanical straps and a strap force of ten to one hundred pounds of force, said step of fastening comprising the steps of:
passing at least a first portion of a first mechanical strap of said set of mechanical straps through an aperture of said first inductor, said first portion comprising a non-conductive material.

### Claim 19 (depends on 14)

The method of claim 14, further comprising the step of:
driving, via a circuit card, said step of alternatingly connecting/disconnecting said delta circuit from the three phase electrical power with said electrical contactor and said second electrical contactor.

### Claim 20 (depends on 19)

The method of claim 19, further comprising the step of:
altering a resistance of a variable resistor on said circuit card to a user configured setting.