Transformer module for a welder

Abstract

An electric arc welder comprising a high switching frequency inverter for driving the primary of an output transformer where the output transformer has a plurality of modules forming the secondary windings of the transformer and each of the modules comprises a first coaxial set of concentric, telescoped tubes separated by a tubular insulator, a second coaxial set of concentric, telescoped conductive tubes separated by a tubular insulator wherein the sets each have an elongated central passage for accommodating the primary and a conductor connecting the tubes into a series circuit. These modules form a transformer for such welder.

1 . (canceled)  
   
   
       2 . The high speed frequency transformer of  claim 36  wherein each of said magnetic cores comprises a plurality of doughnut-shaped rings around one of said tubes.  
   
   
       3 - 4 . (canceled)  
   
   
       5 . The high frequency transformer of  claim 36  wherein each of said first and second modules further includes a conductive assembly comprising a third conductive tube with first and second ends, a fourth conductive tube with first and second ends and a second jumper strap joining said first ends of said third and fourth tubes into a parallel relationship to each other and to said first and second tubes; said third and fourth parallel tubes being telescoped into said passages of said first and second tubes, respectively, and having elongated passages for accommodating said primary winding or windings with said first and second jumper strap spaced from each other; a first tubular insulator between said first and third tubes; a second tubular insulator between said second and fourth tubes; and a center tap connector joining said conductive assembly to a second end of one of said first and second tubes to form said tubes into a series circuit.  
   
   
       6 . A module as defined in  claim 5  wherein said second end of one of said first and second tubes and one end of one of said third and fourth tubes are connected to a rectifier.  
   
   
       7 - 21 . (canceled)  
   
   
       22 . An electric arc welder comprising an output transformer and a high switching frequency inverter for driving the primary of the output transformer, said output transformer having a plurality of modules forming secondary windings, each of said modules comprising a first coaxial set of concentric, telescoped tubes separated by a tubular insulator, a second coaxial set of concentric, telescoped conductive tubes separated by a tubular insulator, said sets each accommodating said primary, and a conductor connecting said tubes into a series circuit.  
   
   
       23 . A welder as defined in  claim 22  wherein said tubes of said modules are each connected to a rectifier to create a positive and negative current output and a circuit connecting said outputs in parallel.  
   
   
       24 . (canceled)  
   
   
       25 . A power source as defined in  claim 44  wherein said tubes of said modules are each connected to a rectifier to create a positive and negative current output and a circuit connecting said outputs in parallel.  
   
   
       26 . A power source as defined in  claim 25  wherein said tubes of said modules are formed by an elongated ribbon helixed around a central axis of said tube.  
   
   
       27 - 34 . (canceled)  
   
   
       35 . A high frequency transformer of an electric arc welder, comprising: 
 a first module having a first module secondary winding section;    a second module having a second module secondary winding section, said first module secondary winding section interconnected with said second module secondary winding section; and    a primary winding through each of said first and second modules.    
   
   
       36 . The high frequency transformer of  claim 35  wherein each of said first and second modules includes: 
 a first conductive tube with first and second ends and a central elongated passage;    a generally parallel second conductive tube with first and second ends and a central elongated passage; and    a magnetic core surrounding each of said first and second tubes, wherein said primary winding is accommodated in said central elongated passages of said first and second tubes, said first ends of said tubes are joined together by a jumper strap, and a circuit forming connector is disposed at said second ends of said tubes.    
   
   
       37 . The high frequency transformer of  claim 35  further including a third module having a third module secondary winding section, said winding sections of said first, second and third modules interconnected and said primary winding through each of said first, second and third modules.  
   
   
       38 . The high frequency transformer of  claim 35  wherein each of said modules has a given current capacity and a total output welding current is the sum of the given current capacities of each of said first and second modules.  
   
   
       39 . The high frequency transformer of  claim 38  wherein said total output exceeds about 1,000 amperes.  
   
   
       40 . The high frequency transformer of  claim 38  wherein the given current capacity of each of said first and second modules is approximately the same.  
   
   
       41 . The high frequency transformer of  claim 35  wherein said first and second modules are readily removable from one another.  
   
   
       42 . The high frequency transformer of  claim 35  wherein the primary is driven by a high frequency inverter.  
   
   
       43 . The welder of  claim 22  wherein said sets of tubes each have an elongated passage accommodating said primary.  
   
   
       44 . The welder of  claim 22  wherein each of said plurality of modules is readily removable from said output transformer.  
   
   
       45 . A power source for electric arc welding, said power source includes a high switching speed inverter for driving the primary of an output transformer with AC primary current, said output transformer having a number of modules each with a given current capacity forming the secondary winding of the output transformer, said modules connected in parallel with the total output welding current being the sum of the current capacities of said separate modules and able to exceed about 1,000 amperes.  
   
   
       46 . A power source as defined in  claim 45  wherein said given current capacities are the same.  
   
   
       47 . A power source as defined in  claim 45  wherein each of said number of modules comprises a first conductive tube with first and second ends; a generally parallel closely adjacent second conductive tube with first and second ends, said tubes each having a central elongated passage accommodating one or more primary windings; a magnetic core surrounding each of said tubes; a jumper strap joining said first ends of said tubes; and, a circuit forming connector at said second ends of said tubes.  
   
   
       48 . A power source as defined in  claim 47  wherein each of said number of modules includes a conductive assembly comprising a third conductive tube with first and second ends, a fourth conductive tube with first and second ends and a second jumper strap joining said first ends of said third and fourth tubes into a parallel relationship to each other and to said first and second tubes; said third and fourth parallel tubes being telescoped into said passages of said first and second tubes, respectively, and having elongated passages accommodating said primary winding or windings with said first and second jumper strap spaced from each other; a first tubular insulator between said first and third tubes; a second tubular insulator between said second and fourth tubes; and a center tap connector joining said conductive assembly to a second end of one of said first and second tubes to form said tubes into a series circuit.