Transformer construction

• US 8,917,156 B2
• Filed: 02/19/2013
• Issued: 12/23/2014
• Est. Priority Date: 11/03/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Enecsys Limited
• Inventors: Garrity, Paul, Silva, Arturo
• Primary Examiner(s): TO, TOAN C
• Application Number:
  US13/771,024
• Publication Number:
  US 20130229834A1
• Time in Patent Office: 672 Days
• Field of Search: 180/65.2, 336/172, 336/173, 336/180, 336/185, 336/186, 336/196, 336/197, 336/198, 336/199, 336/214, 336/215, 336/206, 336/207, 336/208
• US Class Current: 336/221
• CPC Class Codes: H01F 2005/025 wound on coaxial arrangement of two or more formers
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2866 Combination of wires and sheets
• CPC Class Codes: H01F 27/30 Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 27/325 Coil bobbins formers for coils in general H01F5/02
• CPC Class Codes: H01F 27/38 Auxiliary core members; Auxiliary coils or windings
• CPC Class Codes: H01F 41/06 Coil winding
• CPC Class Codes: H01F 41/061 Winding flat conductive wires or sheets
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: Y02E 10/56 Power conversion systems, e.g. maximum power point trackers
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

The invention relates to a transformer construction comprising a plurality of transformer cores configured to share magnetic flux paths and, as a result, at least one of the cores comprises a post and an associated sidewall having an effective cross-sectional area which is less than that of the post. Such a construction may be employed in a power conditioning unit, for example, for a photovoltaic module, which is configured to operate the cores out of phase from each other. Also described is a transformer winding comprising a longitudinal spine having a first turn emanating from a first portion of the spine in a first transverse direction and a second turn emanating from a second portion of the spine in a second transverse direction, wherein the second transverse direction is opposite to the first transverse direction.

Claims

1. A power conditioning unit for providing ac power from a photovoltaic (PV) panel comprising:

a plurality of single phase transformers; and

a plurality of drive circuits arranged to operate the plurality of transformers out of phase from each other;

wherein the transformers are configured to share magnetic flux paths.

2. The power conditioning unit according to claim 1 wherein three transformers are arranged to be operated by respective drive circuits with a 60 degree phase shift therebetween.

3. The power conditioning unit of claim 1, wherein each transformer comprises a primary side and a secondary side, wherein each driver circuits operates a transformer from the primary side of the transformer.

4. The power conditioning unit of claim 3, wherein the plurality of transformers are connected in parallel at their secondary side before feeding into a dc link capacitor that stores energy from the PV panel.

5. The power conditioning unit of claim 1, wherein the plurality of transformers comprises a plurality cores that are conjoined to share magnetic flux paths.

6. The power conditioning unit of claim 5, wherein the plurality of the transformers are operated in a particular sequence to allow the cores to share magnetic flux paths without creating interference.

7. The power conditioning unit of claim 5, wherein at least one of the cores comprises a post and an associated sidewall having an effective cross-sectional area which is less than that of said post.

8. The power conditioning unit of claim 7, wherein the posts and sidewalls are mounted on a common substrate, wherein adjacent posts share a common sidewall, wherein the transformer cores are mounted on one or more separate substrates which are disposed adjacent to each other to allow magnetic flux to flow between the transformer cores.

9. A method of operating a power conditioning unit for providing ac power from a photovoltaic (PV) panel comprising:

providing a plurality of single phase transformers configured to share magnetic flux paths; and

providing a plurality of drive circuits for operating the plurality of transformers out of phase from each other.

10. The method of claim 9, wherein three transformers are operating at 60 degree phase shift therebetween.

11. The method of claim 9, wherein each transformer comprises a primary side and a secondary side, wherein each driver circuits operates a transformer from the primary side of the transformer.

12. The method of claim 11, wherein the plurality of transformers are connected in parallel at their secondary side before feeding into a dc link capacitor that stores energy from the PV panel.

13. The method of claim 9, wherein the plurality of transformers comprise a plurality of cores that are conjoined to share magnetic flux paths.

14. The method of claim 13, wherein the plurality of transformers are operated in a particular sequence to allow the cores to share magnetic flux paths without creating interference.

15. The method of claim 13, wherein at least one of the cores comprises a post and an associated sidewall having an effective cross-sectional area which is less than that of said post.

16. The method of claim 15, wherein the posts and sidewalls are mounted on a common substrate, wherein adjacent posts share a common sidewall, wherein the transformer cores are mounted on one or more separate substrates which are disposed adjacent to each other to allow magnetic flux to flow between the transformer cores.

17. A method for providing ac power from a photovoltaic (PV) panel, the method comprising:

converting dc power from the PV panel in a plurality of single phase transformers having conjoined cores that share magnetic flux paths;

configuring a plurality of drive circuits for operating the plurality of single phase transformers to be at different phases to allow the cores of the transformers to share the magnetic flux paths without interference.

18. The method of claim 17, wherein the plurality of the transformers are operated in a particular sequence to allow the cores to share magnetic flux paths without creating interference.

19. The method of claim 17, wherein three transformers are operating at 60 degree phase shift therebetween.