Optimized electromagnetic transformer component design and methods including improved conductivity composite conductor material
AssigneeCooper Technologies Company
InventorFrank Anthony Doljack
Life of this patent
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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.
Claims46
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;
- 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.
A method of manufacturing an electromagnetic transformer component comprising:
- selecting a reference transformer having reference core made of a reference magnetic material and reference windings made of a reference conductor material;
- providing a composite conductive material having a conductivity greater than a conductivity of the reference conductor material;
- determining a ratio of electrical conductivity (β) of the composite conductor to the electrical conductivity of the reference conductor material;
- determining a new core size with permissible range of values of linear dimension ratio (ξ) or core height ratio (χ) based on the determined ratio of electrical conductivity (β);
- and
- based on the determined ratio of electrical conductivity (β), determining an upper limit and lower limit of an effective diameter ratio (δ) of the composite conductive material relative to the reference conductor material.
Dependencies are inferred from the claim text.