3D-Printed Transformer Insulation With Integrated Winding Paths
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Solution Overview
Problem
Manufacturing inductors and transformers involves sourcing numerous components from different suppliers, leading to time-consuming and costly assembly due to tight tolerances and small form factors, which complicates obtaining a set of parts that fit together effectively.
Innovation Solution
Utilizing additive manufacturing techniques, such as 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 winding formation process directly into the insulator production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used with multiple separate components, then assembly precision can be maintained through tight tolerances, but the number of parts and suppliers increases, leading to higher costs and longer assembly time
Solution Approach 1:
The patent combines the insulator and winding into a single integrated component manufactured via 3D printing. The insulator is printed with embedded winding structures, eliminating the need for separate winding assembly steps and reducing the total part count while maintaining electrical insulation and magnetic coupling functions.
Solution Approach 2:
The 3D printed insulator serves multiple functions simultaneously: it provides electrical insulation between windings, acts as a structural support for the winding patterns, and incorporates the winding paths directly into its geometry. This multi-functionality reduces the number of separate components needed.
2Ease of manufacture
If traditional manufacturing methods are used with multiple separate components, then each component can be optimized independently, but the assembly process becomes time-consuming and expensive due to tight tolerances
Solution Approach 1:
The winding structures are pre-formed as integral parts of the insulator during the 3D printing process itself. The conductive material is deposited or embedded within the insulator geometry before final assembly, eliminating subsequent winding and assembly operations.
Solution Approach 2:
The patent replaces traditional mechanical assembly processes (separate winding, insulation, and assembly steps) with an additive manufacturing process that creates the complete assembly in a single printing operation, significantly reducing assembly time and complexity.
3Adaptability or versatility
If traditional manufacturing methods are used, then standard components can be purchased from suppliers, but the small form factor requires tight tolerances that increase cost and sourcing complexity
Solution Approach 1:
The 3D printing process enables manufacturing of small components with relaxed tolerance requirements compared to traditional precision manufacturing. The additive process naturally accommodates small variations while maintaining functional performance, reducing the stringency of tolerance specifications.
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 decreases production costs, simplifies the sourcing process, and allows for smaller form factors by integrating winding formation within the insulator, thereby reducing the complexity and expense of assembling transformers and inductors.
Implementation Method 1
an insulator for an inductor or transformer may be produced by additive manufacturing techniques, such as 3D printing
Data Source
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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.