Enphase Energy has been granted a patent for methods and apparatus for producing helix windings used in transformers. The apparatus includes an electrically conductive mandrel with an elongated body, a head with an eyelet detail, and a winding structure. The mandrel, head, and non-electroplated portion of the winding structure are covered in an insulating material, while the eyelet detail is surrounded by the insulating material but not covered. GlobalData’s report on Enphase Energy gives a 360-degree view of the company including its patenting strategy. Buy the report here.

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According to GlobalData’s company profile on Enphase Energy, smart energy mgmt systems was a key innovation area identified from patents. Enphase Energy's grant share as of June 2023 was 1%. Grant share is based on the ratio of number of grants to total number of patents.

An apparatus for producing helix windings for transformers

Source: United States Patent and Trademark Office (USPTO). Credit: Enphase Energy Inc

A recently granted patent (Publication Number: US11657963B2) describes an apparatus for producing helix windings used in transformers. The apparatus includes an electrically conductive mandrel with an elongated body, a head with an eyelet detail, and a winding structure along the body. The mandrel, head, and a portion of the winding structure that is not to be electroplated are covered in an insulating material. However, the eyelet detail is surrounded by the insulating material but not covered by it.

The insulating material used in the apparatus is specified to be an epoxy paint. This material helps to protect the mandrel, head, and non-electroplated portion of the winding structure from the electroplating process.

The patent also mentions that the portion of the winding structure that is to be electroplated includes both the top and bottom surfaces of the structure. This ensures that the entire winding structure is properly coated during the electro-deposition process.

The electrically conductive mandrel, which forms the core of the apparatus, is made from titanium. This choice of material provides the necessary conductivity for the electroplating process.

The winding structure itself is described as comprising two three-turn winding structures and a six-turn winding structure. This configuration allows for the production of helix windings with specific characteristics required for transformers.

When the electrically conductive mandrel is placed in an electrolyte solution for the electro-deposition of high-purity copper, the top and bottom surfaces of the winding structure are designed to be electroplated. The electrolyte solution can include copper sulfate, copper cyanide, or copper acetate.

To facilitate the electroplating process, the eyelet detail of the mandrel is configured to connect to a negative terminal of an electroplating power supply when placed in the electrolyte solution.

Overall, this granted patent describes an apparatus that enables the efficient production of helix windings for transformers. The use of an insulating material, specific winding configurations, and the choice of materials contribute to the effectiveness of the apparatus in producing high-quality windings.

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GlobalData, the leading provider of industry intelligence, provided the underlying data, research, and analysis used to produce this article.

GlobalData Patent Analytics tracks bibliographic data, legal events data, point in time patent ownerships, and backward and forward citations from global patenting offices. Textual analysis and official patent classifications are used to group patents into key thematic areas and link them to specific companies across the world’s largest industries.