POWER CONVERTER METHOD AND APPARATUS

• US 20120286914A1
• Filed: 05/13/2011
• Published: 11/15/2012
• Est. Priority Date: 06/17/2004
• Status: Active Grant

• Current Assignee: CTM Magnetics, Inc.
• Original Assignee: CTM Magnetics, Inc.
• Inventors: MacLennan, Grant A.
• Granted Patent: US 8,373,530 B2
• Time in Patent Office: Days
• US Class Current: 336/60
• CPC Class Codes: H01F 27/10 Liquid cooling
• CPC Class Codes: H01F 27/2876 Cooling cooling transformers and inductances in general H01F27/08
• CPC Class Codes: H01F 27/2895 Windings disposed upon ring cores
• CPC Class Codes: H01F 27/324 Insulation between coil and core, between different winding sections, around the coil; Other insulation structures

Abstract

The invention comprises a power converter method and apparatus, which is optionally part of a filtering method and apparatus. A corona potential is the potential for long term breakdown of winding wire insulation due to the high electric potentials between winding turns winding a mid-level power inductor in a converter system. The high electric potential creates ozone, which breaks down insulation coating the winding wire and results in degraded performance or failure of the inductor. In one embodiment, the inductor is configured with inductor winding spacers, such as a main inductor spacer and/or inductor segmenting winding spacers. The spacers are used to space winding turns of a winding coil about an inductor. The insulation of the inductor spacer minimizes energy transfer between windings and thus minimizes corona potential, formation of corrosive ozone through ionization of oxygen, correlated breakdown of insulation on the winding wire, and electrical shorts in the inductor.

Claims

1. An electrical system apparatus for processing power, comprising:

a single phase inductor comprising a core and a winding wrapped about said core; and

at least two inductor winding spacers proximately contacting and extending radially outward from an outer surface of said core,

wherein said inductor winding spacers segment an outer surface of said core into sections,

wherein said inductor winding spacers separate at least two individual turns of said winding.

2. The apparatus of claim 1, wherein said inductor winding spacers comprise:

a main inductor spacer separating a first turn of said winding from a terminal turn of said winding, said first turn comprising a first loop around said core proximate an input terminal, said terminal turn comprising a second loop about said core proximate an output terminal; and

a segmenting spacer separating two consecutive turns of said winding about said core.

3. The apparatus of claim 1, wherein at least one of said inductor winding spacers about circumferentially surrounds a cross-section of a portion of said core.

4. The apparatus of claim 1, wherein at least three of said inductor winding spacers proximately contact an inner surface of said core, wherein said inner surface forms an aperture through said inductor.

5. The apparatus of claim 1, wherein a first spacer of said at least two inductor spacers separates an initial input turn of said winding from a terminal output turn of said winding, wherein a second spacer of said at least two inductor spacers separates two consecutive turns of said winding, wherein a first thickness of said first spacer is greater than a second thickness of said second spacer.

7. The apparatus of claim 1, said inductor configured to convert power within the range of about one thousand five hundred volts to thirty-five thousand volts.

8. The apparatus of claim 1, wherein at least one of said inductor winding spacers comprises a rotated spacer, said rotated spacer comprising a rotated configuration, wherein said rotated configuration comprises an alignment of said rotated spacer along a front face of said inductor not aligned with an axis running perpendicular to said front face of said inductor.

9. The apparatus of claim 1, wherein at least one of said inductor winding spacers varies in distance along both an x-axis and a y-axis as a function of radial distance from a center of a front face of said inductor, wherein said x-axis and said y-axis form a plane parallel to a face of said inductor.

10. The apparatus of claim 1, said inductor configured to:

carry a magnetic field of greater than one thousand one hundred Gauss and less than five thousand Gauss at two hundred Oersteds; and

transmit a current of at least forty amperes.

6. An electrical system apparatus for processing power, comprising:

a single phase inductor comprising a core and a winding wrapped about said core; and

at least two inductor winding spacers proximately contacting and extending radially outward from an outer surface of said core,

wherein said inductor winding spacers segment an outer surface of said core into sections,

wherein said inductor winding spacers separate at least two individual turns of said winding, and

wherein a first of said inductor winding spacers comprises a first cross-section with a first electrically insulating resistivity, wherein a second of said inductor winding spacers comprises a second cross-section with a second electrically insulating resistivity at least twenty percent different from said first electrically insulating resistivity.

11. An electrical system apparatus for processing power, comprising:

a single phase inductor comprising a core and a winding wrapped about said core;

at least two inductor winding spacers proximately contacting and extending radially outward from an outer surface of said core,

wherein said inductor winding spacers segment an outer surface of said core into sections, and

wherein said inductor winding spacers separate at least two individual turns of said winding; and

a plurality of capacitors configured to process the power, said plurality of capacitors distributed in three dimensions in an array, said array comprising;

a first row of said capacitors carrying a first phase of a multi-phase power source;

a second row of said capacitors carrying a second phase of said multi-phase power source; and

a common neutral buss bar running between said first row and said second row.

12. An electrical system apparatus for processing power, comprising:

a single phase inductor comprising a core and a winding wrapped about said core;

at least two inductor winding spacers proximately contacting and extending radially outward from an outer surface of said core; and

a container configured to hold a liquid coolant in proximate contact with at least said winding and said at least two inductor winding spacers of said inductor,

wherein said inductor winding spacers segment an outer surface of said core into sections, and

wherein said inductor winding spacers separate at least two individual turns of said winding.

13. (canceled)

14. (canceled)

15. (canceled)

16. (canceled)

17. (canceled)

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)