The invention comprises an inductor, such as used in processing transmission of a 3-phase power system. The inductor comprises a flat/rectangular winding with a narrow edge of the flat winding wound around a core, where the width of the winding exceeds three times the height of the inductor facing edge of the winding. The inductor optionally comprises a distributed gap particle core and/or is wound in parallel with multiple windings. Optionally, the inductor is used as part of an equal coupling common mode electrical system for processing the 3-phase transmission and/or a high frequency inverter comprising a switching device, such as a silicon carbide metal-oxide-semiconductor field-effect transistor.
The invention comprises a fabricated inductor winding apparatus and method of use/manufacture thereof, where the inductor has a core and a fabricated winding. The fabricated winding comprises a plurality of turns, a first turn of the plurality of turns comprising a first sub-section and a second sub-section, the first sub-section electrically connected to the second sub-section with a first non-wire electrical connection during an assembly step of the inductor and the second sub-section of the first turn electrically connected to a second turn with a second electrical connection formed during a winding step.
The invention comprises a multi-inductor mounting/cooling apparatus and method of use thereof comprising: an elongated tube having a first elongated section and a second elongated section separated by at least a first longitudinal split down a length of the elongated tube and at least three inductors affixed to a baseplate, the at least three inductors positioned within the elongated tube, the at least three inductors comprising a plurality of connectors extending radially outward through at least one aperture formed between the first elongated section and the second elongated section. Optionally and preferably a fan is positioned within and/or at an end of the elongated tube.
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;
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.
The invention comprises a harmonic filter apparatus and method of use thereof for magnetically isolating and filtering individual phases of three-phase power comprising a delta circuit that includes: (1) a first leg connecting to a second leg and a third leg and (2) first circuitry on the first leg matching second circuitry on the second leg, the first circuitry comprising at least two contactors electrically wired in parallel, the harmonic filter magnetically isolating individual phases of three-phase power, where inductor—coupled inductor pairs couple apexes of the delta circuit to individual phases of the three-phase power.
H01F 27/26 - Fastening parts of the core togetherFastening or mounting the core on casing or support
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
The invention comprises a harmonic filter apparatus and method of use thereof for magnetically isolating and filtering individual phases of three-phase power comprising a delta circuit that includes: (1) a first leg connecting to a second leg and a third leg and (2) first circuitry on the first leg matching second circuitry on the second leg, the first circuitry comprising at least two contactors electrically wired in parallel, the harmonic filter magnetically isolating individual phases of three-phase power, where inductor—coupled inductor pairs couple apexes of the delta circuit to individual phases of the three-phase power.
The invention comprises a method for fastening an inductor, comprising an aperture therethrough, to a mounting surface with a set of at least two mechanical straps and a strap force of ten to one hundred pounds of force per strap, the step of fastening further comprising the step of: passing at least a first portion of each of a first and second mechanical strap of the set of mechanical straps through the aperture and on opposing sides of the aperture, the first portion comprising a non-conductive material, where the inductor winding is fabricated during installation and/or the inductor is a component of a harmonic filter magnetically isolating and filtering individual phases of three phase power.
The invention comprises an inverter/converter yielding high frequency harmonics and/or non-sixty Hertz output coupled to a high frequency inductor-capacitor filter apparatus. For example, an inverter/converter apparatus is provided that uses a silicon carbide transistor to output power having a carrier frequency modulated by a fundamental frequency and a set of harmonic frequencies, where the minimum carrier frequency is above that usable by an iron-steel inductor, such as greater than ten kiloHertz at fifty or more amperes. An inductor-capacitor filter, comprising an inductor having a distributed gap core material, receives power output from the inverter/converter and processes the power by passing the fundamental frequency while reducing amplitude of the harmonic frequencies.
H02P 27/08 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters with pulse width modulation
The invention comprises a method for manufacturing an inductor, comprising the steps of: casting a cast winding comprising an inner cavity; inserting a first inductor core subsection into the inner cavity; inserting a second inductor core subsection into the inner cavity; and mechanically coupling the first inductor core subsection to the second inductor core subsection to form an inductor core wound by the cast windings. The method of manufacturing optionally includes the steps of: forming at least a portion of the cast winding into an arced helical shape; forming the first inductor core subsection and the second inductor core subsection into elements of a torpid shaped inductor core; deforming the cast winding to physically allow the step of inserting the first inductor core subsection into the inner cavity; and/or deforming at least a portion of the cast winding into an arced helical coil shape after the step of inserting.
H02M 1/12 - Arrangements for reducing harmonics from AC input or output
H01F 27/30 - Fastening or clamping coils, windings, or parts thereof togetherFastening or mounting coils or windings on core, casing, or other support
H01F 37/00 - Fixed inductances not covered by group
H01F 27/26 - Fastening parts of the core togetherFastening or mounting the core on casing or support
H01F 27/32 - Insulating of coils, windings, or parts thereof
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
The invention comprises an apparatus, comprising: a toroid shaped inductor and a cooling jacket including at least two sections joined to encase the toroid shaped inductor, where the cooling jacket has an inner toroid shaped surface separated by a coolant flow gap from the toroid shaped inductor. Optionally, the inductor comprises a cast winding, a cast heat sink element of the cast winding protruding from a longitudinal length of a turn of the winding, and/or a distributed gap pressed powder inductor core.
H01F 27/30 - Fastening or clamping coils, windings, or parts thereof togetherFastening or mounting coils or windings on core, casing, or other support
H01F 27/32 - Insulating of coils, windings, or parts thereof
H01F 37/00 - Fixed inductances not covered by group
H02M 1/12 - Arrangements for reducing harmonics from AC input or output
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
13.
Flat winding / equal coupling common mode inductor apparatus and method of use thereof
The invention comprises an inductor, such as used in processing transmission of a 3-phase power system. The inductor comprises a flat/rectangular winding with a narrow edge of the flat winding wound around a core, where the width of the winding exceeds three times the height of the inductor facing edge of the winding. The inductor optionally comprises a distributed gap particle core and/or is wound in parallel with multiple windings. Optionally, the inductor is used as part of an equal coupling common mode electrical system for processing the 3-phase transmission and/or a high frequency inverter comprising a switching device, such as a silicon carbide metal-oxide-semiconductor field-effect transistor.
H02M 1/12 - Arrangements for reducing harmonics from AC input or output
H01F 27/30 - Fastening or clamping coils, windings, or parts thereof togetherFastening or mounting coils or windings on core, casing, or other support
H01F 37/00 - Fixed inductances not covered by group
H01F 27/26 - Fastening parts of the core togetherFastening or mounting the core on casing or support
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
A high frequency inductor filter cooling apparatus, method of manufacture, and method of use thereof is described. In one embodiment, an inductor is potted in an epoxy-silica mixture to facilitate thermal transfer from the inductor. The inductor is optionally used with a capacitor to filter/invert/convert power. The inductor optionally comprises a distributed gap core and/or a powdered core material. In one example, a minimum carrier frequency used with the filter is above that usable by a traditional wound iron-steel inductor, such as greater than seven hundred or ten thousand Hertz at fifty or more amperes. Optionally, the inductor is used in an inverter/converter apparatus in conjunction with a notched low-pass filter, a low pass filter combined with a notch filter and a high frequency roll off filter, and/or one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.
H01F 7/06 - ElectromagnetsActuators including electromagnets
H01F 41/00 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformersApparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
H01F 27/30 - Fastening or clamping coils, windings, or parts thereof togetherFastening or mounting coils or windings on core, casing, or other support
H01F 37/00 - Fixed inductances not covered by group
H02M 1/12 - Arrangements for reducing harmonics from AC input or output
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
15.
Equal coupling common mode inductor apparatus and method of use thereof
The invention comprises an electrical system apparatus for processing three-phase power, comprising: a first, second, and third inductor connected on a first end to a first common magnetic field carrying plate and connected on a second end to a second common magnetic field carrying plate, where the three inductors are equidistant from each other and/or equidistance from a central axis, which yields an equal coupling common mode inductor-capacitor based filtering apparatus. Generally, inductor placement symmetry and/or equal magnetic field permeabilities between each pair of the three inductors balances magnetic fields within each inductor at each point of time, where each of the three inductors is connected to a single phase of three-phase power, the three phases offset from each other by one-third of a period.
H03H 1/00 - Constructional details of impedance networks whose electrical mode of operation is not specified or applicable to more than one type of network
H01F 27/30 - Fastening or clamping coils, windings, or parts thereof togetherFastening or mounting coils or windings on core, casing, or other support
H01F 37/00 - Fixed inductances not covered by group
H02M 1/12 - Arrangements for reducing harmonics from AC input or output
H02K 11/02 - Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for suppression of electromagnetic interference
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
16.
Flat winding / equal coupling common mode inductor apparatus and method of use thereof
The invention comprises an inductor, such as used in processing transmission of a 3-phase power system. The inductor comprises a flat/rectangular winding with a narrow edge of the flat winding wound around a core, where the width of the winding exceeds three times the height of the inductor facing edge of the winding. The inductor optionally comprises a distributed gap particle core and/or is wound in parallel with multiple windings. Optionally, the inductor is used as part of an equal coupling common mode electrical system for processing the 3-phase transmission and/or a high frequency inverter comprising a switching device, such as a silicon carbide metal-oxide-semiconductor field-effect transistor.
The invention comprises a high frequency inductor filter apparatus and method of use thereof. In one embodiment, an inductor is used to filter/convert power, where the inductor comprises a distributed gap core and/or a powdered core material. The inductor core is wound with one or more turns, where multiple turns are optionally electrically wired in parallel. In one example, the minimum carrier frequency is above that usable by an iron-steel inductor, such as greater than ten kiloHertz at fifty or more amperes. The core is optionally an annular core, solid rod core, or a core used for multiple phases, such as a ‘C’ or ‘E’ core. Optionally, the inductor is used in an inductor/converter apparatus, where output power has a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies, in conjunction with one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.
H02P 27/08 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters with pulse width modulation
18.
Distributed gap inductor potting apparatus and method of use thereof
A high frequency inductor filter cooling apparatus and method of use thereof is described. In one embodiment, an inductor is potted in an epoxy-silica mixture to facilitate thermal transfer from the inductor. The inductor is optionally used to filter/invert/convert power. The inductor comprises a distributed gap core and/or a powdered core material. In one example, the minimum carrier frequency is above that usable by an iron-steel inductor, such as greater than ten kiloHertz at fifty or more amperes. Optionally, the inductor is used in an inverter/converter apparatus, where output power has a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies, in conjunction with a notched low-pass filter, a low pass filter combined with a notch filter and a high frequency roll off filter, and/or one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.
H02M 7/539 - Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters with automatic control of output wave form or frequency
H01F 41/02 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformersApparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils or magnets
The invention comprises an inverter/converter yielding high frequency harmonics and/or non-sixty Hertz output coupled to a high frequency inductor-capacitor filter apparatus. For example, an inverter/converter apparatus is provided that uses a silicon carbide transistor to output power having a carrier frequency modulated by a fundamental frequency and a set of harmonic frequencies, where the minimum carrier frequency is above that usable by an iron-steel inductor, such as greater than ten kiloHertz at fifty or more amperes. An inductor-capacitor filter, comprising an inductor having a distributed gap core material, receives power output from the inverter/converter and processes the power by passing the fundamental frequency while reducing amplitude of the harmonic frequencies.
H01F 37/00 - Fixed inductances not covered by group
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
A high frequency inductor filter cooling apparatus, method of manufacture, and method of use thereof is described. In one embodiment, an inductor is potted in an epoxy-silica mixture to facilitate thermal transfer from the inductor. The inductor is optionally used with a capacitor to filter/invert/convert power. The inductor optionally comprises a distributed gap core and/or a powdered core material. In one example, a minimum carrier frequency used with the filter is above that usable by a traditional wound iron-steel inductor, such as greater than seven hundred or ten thousand Hertz at fifty or more amperes. Optionally, the inductor is used in an inverter/converter apparatus in conjunction with a notched low-pass filter, a low pass filter combined with a notch filter and a high frequency roll off filter, and/or one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.
H01F 7/06 - ElectromagnetsActuators including electromagnets
H01F 41/00 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformersApparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
H01F 27/30 - Fastening or clamping coils, windings, or parts thereof togetherFastening or mounting coils or windings on core, casing, or other support
H01F 37/00 - Fixed inductances not covered by group
H02M 1/12 - Arrangements for reducing harmonics from AC input or output
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
21.
Distributed gap inductor filter apparatus and method of use thereof
The invention comprises a high frequency inductor filter apparatus and method of use thereof. In one embodiment, an inductor is used to filter/convert power, where the inductor comprises a distributed gap core and/or a powdered core material. The inductor core is wound with one or more turns, where multiple turns are optionally electrically wired in parallel. In one example, the minimum carrier frequency is above that usable by an iron-steel inductor, such as greater than ten kiloHertz at fifty or more amperes. The core is optionally an annular core, solid rod core, or a core used for multiple phases, such as a ‘C’ or ‘E’ core. Optionally, the inductor is used in an inductor/converter apparatus, where output power has a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies, in conjunction with one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.
H03H 1/00 - Constructional details of impedance networks whose electrical mode of operation is not specified or applicable to more than one type of network
H03H 7/075 - Ladder networks, e.g. electric wave filters
H01F 37/00 - Fixed inductances not covered by group
H01F 27/26 - Fastening parts of the core togetherFastening or mounting the core on casing or support
H01F 27/30 - Fastening or clamping coils, windings, or parts thereof togetherFastening or mounting coils or windings on core, casing, or other support
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials thereforSelection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
22.
Distributed gap inductor filter apparatus and method of use thereof
The invention comprises a high frequency inductor filter apparatus coupled with an inverter yielding high frequency harmonics and/or non-sixty Hertz output. For example, an inductor/converter apparatus is provided that uses a silicon carbide transistor to output power having a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies. A filter, comprising an inductor having a distributed gap core material and optional magnet wires, receives power output from the inverter/converter and processes the power by passing the fundamental frequency while reducing amplitude of the harmonic frequencies.
H02P 1/00 - Arrangements for starting electric motors or dynamo-electric converters
H02P 3/00 - Arrangements for stopping or slowing electric motors, generators, or dynamo-electric converters
H02P 7/06 - Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current
H02M 1/12 - Arrangements for reducing harmonics from AC input or output
H01G 4/38 - Multiple capacitors, i.e. structural combinations of fixed capacitors
H01G 4/40 - Structural combinations of fixed capacitors with other electric elements not covered by this subclass, the structure mainly consisting of a capacitor, e.g. RC combinations
23.
High frequency inductor filter apparatus and method of use thereof
A high frequency inductor filter apparatus coupled with an inverter yielding high frequency harmonics and/or non-sixty Hertz output is described. For example, an inductor/converter apparatus is provided using a silicon carbide transistor that outputs power having a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies. A filter, comprising an inductor having a distributed gap core material and optional magnet wires, receives power output from the inverter/converter and processes the power by passing the fundamental frequency while reducing amplitude of the harmonic frequencies.
The invention comprises an electrical apparatus and method of manufacture. The apparatus includes a substantially annular inductor comprising an inductor core composed of at least a distributed gap material. The distributed gap material includes particles of alternating layers of magnetic and non-magnetic materials separated by a gap material. The particles comprise an average layer thickness of less than about one hundred micrometers, where a majority of said layered particles comprise an average cross sectional size of less than about one millimeter. The inductor is cooled using at least one of: a thermally conductive potting material, a liquid coolant in direct contact with the inductor, a cooling line through the potting material or liquid coolant, and a chill coil in a container about the potting material and/or the liquid coolant.
The invention comprises a high frequency inductor filter apparatus coupled with an inverter yielding high frequency harmonics and/or non-sixty Hertz output. For example, an inductor/converter apparatus is provided that uses a silicon carbide transistor to output power having a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies. A filter, comprising an inductor having a distributed gap core material and optional magnet wires, receives power output from the inverter/converter and processes the power by passing the fundamental frequency while reducing amplitude of the harmonic frequencies.
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.
The invention comprises a phase change inductor cooling system. The cooling system uses a non-conductive refrigerant in proximate and/or in direct contact with an inductor. Heat from the inductor changes the refrigerant from a liquid to a gas phase, which removes heat from the inductor. The gas phase refrigerant is subsequently removed from the inductor to remove heat from the environment about the inductor. The refrigerant is optionally recirculated using the steps of condensing and/or compressing the refrigerant prior to reintroduction into the environment proximate and/or in direct contact with the inductor.
The invention comprises an inductor configured for filtering medium and/or high voltage power. The inductor includes an inductor core formed of a plurality of coated magnetic particles, each of a majority of the coated magnetic particles including: a magnetic particle core and a non-magnetic coating about a corresponding magnetic particle core. The inductor optionally includes: (1) a main inductor spacer separating a first turn of a winding from a terminal turn of the winding and (2) a segmenting spacer separating two consecutive turns of the winding about said core. The inductor is configured to convert power into an output current, such as power of at least one thousand five hundred volts with an input current of at least fifty amperes.
The invention comprises an inductor mounting method and apparatus. An about annular inductor is mounted using a non-conducting mount element passing at least into a center opening of the inductor. Mounting hardware forces an edge surface of the mount into proximate contact with an edge of the inductor, where the mount and mounting hardware minimally contact the inductor. The mount optionally includes holes and/or grooves to further reduce mount/inductor contact, which aids liquid, convective, and/or radiative cooling of the inductor. The inductor is optionally composed of particles of magnetic material coated with carbon and embedded into an epoxy to yield a distributed gap material.
The invention comprises an electrical system including at least an inductor configured to carry a magnetic field of less than about thirty Gauss/Oersted. The inductor comprises an inductor core having a plurality of coated particles, each of a majority of the coated particles comprising: at least three layers, a first set of substantially magnetic alternating layers composed of an alloy, and a second set of substantially non-magnetic alternating layers, where the coated particles are about evenly distributed in the inductor core. Optionally, a thermal transfer agent is used to cool the inductor, where the thermal transfer agent includes at least one of: a thermally conductive potting material and a substantially non-conductive liquid coolant in direct contact with the inductor. Optionally, a cooling coil passes through the potting material and/or the liquid coolant.
Methods and apparatus for electrical components according to various aspects of the present invention may be implemented in conjunction with an electrical system comprising a heat generating component and a cooling system. The cooling system may comprise a cooling channel and a coolant. The coolant is disposed within the cooling channel and in thermal contact with the heat generating component.
The invention comprises an electrical apparatus and method of manufacture. The apparatus includes a substantially annular inductor comprising an inductor core composed of at least a distributed gap material. The distributed gap material includes particles of alternating layers of magnetic and non-magnetic materials separated by a gap material. The particles comprise an average layer thickness of less than about one hundred micrometers, where a majority of said layered particles comprise an average cross sectional size of less than about one millimeter. The inductor is cooled using at least one of: a thermally conductive potting material, a liquid coolant in direct contact with the inductor, a cooling line through the potting material or liquid coolant, and a chill coil in a container about the potting material and/or the liquid coolant.
The invention comprises a liquid cooled inductor system including at least an inductor and an immersion fluid directly contacting at least a portion of the inductor, such as an inductor core and/or an inductor winding. The immersion fluid is a substantially non-electrically conducting fluid. Preferably, the inductor comprises an inductor core, such as an annularly shaped core, having a plurality of sub-millimeter sized coated particles having alternating magnetic and non-magnetic layers. Optionally, a cooling coil passes through the immersion fluid, the cooling coil carrying a liquid coolant used to remove heat from the inductor.
The invention comprises a potted inductor, where a solid potting material substantially contacting the inductor enhances cooling of the inductor. The inductor comprises an annular core composed of a distributed gap material, where the distributed gap material includes sub-millimeter particles of alternating magnetic and non-magnetic layers separated by gaps. The potting material includes a urethane, resin, epoxy, or the like combined with a lower thermal impedance additive, such as a silica sand or an aluminum oxide. Optionally, one or more cooling lines direct a circulating coolant flow through the potting material, around the inductor, and/or through the inductor.
The invention comprises an inductor mounting method and apparatus. An about annular inductor is mounted using a non-conducting clamp element passing at least into a center opening of the inductor. Mounting hardware forces the clamp element toward a mounting surface to edge mount the inductor, where the mounting hardware, non-conducting clamp element, and mounting surface minimally contact the inductor. The minimal contact allows greater surface area for liquid, convective, and/or radiative cooling of the inductor. The inductor is optionally composed of particles of magnetic material coated with carbon and embedded into an epoxy to yield a distributed gap material.
The invention comprises an inductor configured for filtering medium and/or high voltage power. The inductor includes an inductor core formed of a plurality of coated magnetic particles, each of a majority of the coated magnetic particles including: a magnetic particle core and a non-magnetic coating about a corresponding magnetic particle core. The inductor optionally includes: (1) a main inductor spacer separating a first turn of a winding from a terminal turn of the winding and (2) a segmenting spacer separating two consecutive turns of the winding about said core. The inductor is configured to convert power into an output current, such as power of at least one thousand five hundred volts with an input current of at least fifty amperes.
Methods and apparatus according to various aspects of the present invention may operate in conjunction with an inductor. For example, n inverter/converter system according to various aspects of the present invention may include an inductor comprising a substantially annular core and a winding. The inductor may be configured for high current applications and exhibit a permeability of less than thirteen delta Gauss per delta Oersted at a load of four hundred Oersteds.
Methods and apparatus for electromagnetic components comprise a core and a winding. The core and winding are configured to provide smaller and more effective electromagnetic components.
09 - Scientific and electric apparatus and instruments
Goods & Services
Apparatus and instruments for conveying, distributing, transforming, storing, regulating or controlling electric current; Distribution transformers; Electric transformers; Electric voltage transformers; Electrical inductors; Electrical relays and transformers; Electrical transformers; Electrical transformers; Low pass inductor filter used in high power electrical applications; Power transformers for amplification; Step down transformers; Step up transformers; Transformers; Welding transformers
40.
Methods and apparatus for electromagnetic component
Methods and apparatus for electromagnetic components comprise a core and a winding. The core and winding are configured to provide smaller and more effective electromagnetic components.
Methods and apparatus according to various aspects of the present invention may be implemented in conjunction with a inductor mount mounting to a mounting surface. The inductor mount may comprise an inductor having a center opening, and a surface area encompassing all of a front face, a back face, an inner surface about the center opening, and an outer edge concentric about the center opening. The inductor mount may further include mounting hardware holding the outer edge of then inductor to the mounting surface. A cooling element moves air into contact with the front face, through the center opening, and around the outer edge of the inductor. In various embodiments, the mounting hardware contacts less that ten percent of the surface area of the inductor.
Methods and apparatus for electromagnetic components comprise a core and a winding. The core and winding are configured to provide smaller and more effective electromagnetic components.
