3D-Printed Transformer Insulation With Integrated Winding Passages
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Solution Overview
Problem
Manufacturing inductors and transformers involves sourcing numerous components from different suppliers, leading to high costs and complexity due to tight tolerances and small form factors, making it time-consuming to obtain parts that fit together effectively.
Innovation Solution
Utilizing 3D printing to create an insulator that acts as a mold for forming windings, reducing the number of parts and suppliers needed by integrating the insulator with the magnetic core and forming conductive windings within the insulator's passages through techniques like molten conductor filling or electroplating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used to source multiple components from different suppliers, then manufacturing precision can be maintained, but device complexity and production time increase significantly
Solution Approach 1:
The patent combines multiple separate components (insulator, winding form, and winding) into a single integrated 3D-printed insulator structure. The insulator is designed with internal passages that directly form the winding paths, eliminating the need for separate winding forms and reducing assembly steps. This merging approach maintains manufacturing precision while significantly reducing device complexity.
Solution Approach 2:
The 3D-printed insulator serves multiple functions simultaneously: it provides electrical insulation, structural support, winding form definition, and thermal management pathways. By making the insulator multi-functional, the patent reduces the total number of parts needed while maintaining the precision required for component fit and assembly.
2Ease of manufacture
If traditional manufacturing methods are used with multiple separate components, then ease of manufacture is maintained for individual parts, but productivity decreases due to assembly complexity
Solution Approach 1:
By merging the insulator and winding form into a single 3D-printed component, the patent eliminates multiple assembly steps. The winding is formed directly within the insulator's internal passages, reducing assembly complexity and improving productivity while maintaining ease of manufacture through additive manufacturing.
Solution Approach 2:
The 3D-printed insulator is manufactured with pre-formed internal passages that define the exact winding paths before the winding process begins. This preliminary structuring of the insulator eliminates the need for complex alignment and positioning during assembly, thereby improving productivity while keeping the manufacturing process simple.
3Strength
If traditional solid insulator designs are used, then structural strength is maintained, but thermal performance deteriorates due to poor heat dissipation
Solution Approach 1:
The patent introduces hollow passages within the solid insulator structure, creating a porous-like internal architecture. These passages allow for improved thermal management by enabling coolant flow or heat dissipation pathways while maintaining the overall structural integrity of the insulator through its solid external form and strategically placed support features.
Solution Approach 2:
The patent transitions from a solid three-dimensional insulator to a three-dimensional structure with internal hollow passages, adding a new dimensional aspect for thermal management. The hollow passages create internal volume for coolant flow or heat dissipation while the external solid structure maintains mechanical strength, effectively addressing both requirements simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces part counts, production costs, and form factors, simplifying the assembly process and enhancing thermal performance by allowing for hollow passages that aid in heat dissipation.
Implementation Method 1
forming conductive windings within the insulator's passages through techniques like molten conductor filling or electroplating
Implementation Method 2
enhancing thermal performance by allowing for hollow passages that aid in heat dissipation
Data Source
AI summary
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.