Insulation and integrated heat sink for high frequency, low output voltage toroidal inductors and transformers
First Claim
1. A transformer comprising:
- a toroidal core;
a primary winding wrapped about the toroidal core as a spaced single layer of wire; and
a secondary winding wrapped about the primary winding to form a helix.
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Abstract
Toroidal transformer and inductor configurations are described that allow for greater heat transfer away from internal device components. The inventive transformer allows for higher thermal and electrical efficiency, as well as for more efficient use of expensive components, such as copper wire. In one embodiment, a toroidal transformer provides access for cooling air by forming the primary winding from a single layer of thick wire and a secondary winding of few turns such that most of the primary winding is exposed to air flow. In another embodiment, a heat sink is positioned between the core and primary windings to conduct heat away from the transformer.
25 Citations
20 Claims
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1. A transformer comprising:
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a toroidal core;
a primary winding wrapped about the toroidal core as a spaced single layer of wire; and
a secondary winding wrapped about the primary winding to form a helix. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A transformer comprising:
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a toroidal core having its outer circumference forming an approximately cylindrical surface;
a heat sink wrapped substantially along said cylindrical surface, where said heat sink includes a copper strap having an electrical insulation that is thermally conductive; and
a primary winding wrapped about the heat sink. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of constructing a transformer comprising the steps of:
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(1) wrapping a margin tape around a section of a toroidal core;
(2) wrapping a heat sink around the outer circumference of said toroidal core, where said heat sink includes a copper strap having an electrical insulating, thermally conductive sleeve covering that portion of said heat sink in contact with the core and having the exposed ends of said strap extend from the outer circumference of said core;
(3) winding a primary winding on said core with the sleeved portion of said heat sink sandwiched between said core and said primary winding; and
(4) wrapping a secondary winding over said primary winding. - View Dependent Claims (18, 19, 20)
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Specification