INSULATION FOR TRANSFORMER OR INDUCTOR
An electrical component includes a magnetic core, an insulator, and a first winding. The insulator includes a first aperture disposed about a first portion of the core and a first insulator passage extending through the insulator, encircling the first aperture. The first winding extends through the first insulator passage and conducts an electrical current.
1 . A process of manufacturing an insulator for a transformer or an inductor, the process comprising:
forming the insulator having a plurality of insulator passages within a structure of the insulator, via an additive manufacturing technique, the plurality of insulator passages being (i) fluidically coupled together; (ii) configured for housing one or more windings; and (ii) arranged such that they define one or more apertures within the insulator;
forming the one or more windings within the plurality of insulator passages; and
installing a magnetic core such that it extends through the one or more apertures.
2 . The process of claim 1 , wherein the additive manufacturing technique is 3D printing.
3 . The process of claim 1 , wherein the additive manufacturing technique is layered manufacturing.
4 . The process of claim 1 , wherein a set of the plurality of insulator passages are isolated from one another.
5 . The process of claim 2 , wherein a set of the plurality of insulator passages are connected to one another.
6 . The process of claim 1 , wherein the one or more windings are formed by filling the plurality of insulator passages with a molten conductor.
7 . The process of claim 6 , wherein the molten conductor is copper.
8 . The process of claim 7 , wherein the molten conductor is a copper alloy.
9 . The process of claim 6 , wherein the one or more windings are formed by electroplating a plurality of interior walls of the plurality of insulator passages.
10 . The process of claim 9 , wherein the one or more windings include hollow passages.
11 . The process of claim 10 , wherein the hollow passages are unfilled.
12 . The process of claim 10 wherein the hollow passages are filled with a material.
13 . The process of claim 10 , wherein the hollow passages are used to flow a liquid or gas fluid through the one or more windings.
14 . The process of claim 1 , wherein the magnetic core is formed by an additive manufacturing process.
15 . The process of claim 14 , wherein the magnetic core is formed at the same time as the insulator.
16 . The process of claim 15 , wherein the magnetic core is formed by the same additive manufacturing process as the insulator.
17 . The process of claim 1 , wherein the magnetic core includes a first portion that extends through two or more of the one or more apertures.
18 . The process of claim 14 , wherein the magnetic core includes a second portion that extends through two or more of the one or more apertures.
19 . The process of claim 1 , wherein the insulator has one aperture.
20 . The process of claim 19 , wherein the magnetic core is a single piece that extends through the one aperture.