Adjustable Leakage Inductance Transformer via Winding Overlap Control
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Solution Overview
Problem
Conventional transformers fail to adjust leakage inductance within an acceptable range, leading to either excessive or insufficient power loss during voltage regulation, which affects electric conversion efficiency.
Innovation Solution
A transformer design with adjustable leakage inductance is achieved by varying the overlap ratio of the primary and secondary winding coils through the use of adjusting elements, such as stop blocks or insulating tapes, which control the coupling coefficient and leakage inductance by altering the overlap region and non-overlap region ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the primary winding coil and secondary winding coil are overlapped and wound around the bobbin, then the coupling coefficient is increased and leakage inductance is reduced, but the electric conversion efficiency deteriorates due to excessive power loss
Solution Approach 1:
The winding space on the bobbin is segmented into multiple sections along the winding direction. The primary winding coil and secondary winding coil are arranged in different sections, creating controlled overlap regions and non-overlap regions. This segmentation allows precise control of the coupling coefficient while maintaining acceptable power loss levels.
2Reliability
If the primary winding coil and secondary winding coil are completely separated, then the leakage inductance is increased, but the electric conversion efficiency deteriorates due to insufficient power transfer
Solution Approach 1:
The design provides dynamic adjustability of the overlap ratio between primary and secondary winding coils. By varying the overlap ratio, the transformer can be optimized for different operating conditions, achieving the desired balance between leakage inductance and power transfer efficiency for specific applications.
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 design allows for precise adjustment of leakage inductance and coupling coefficient, enabling optimal electric conversion efficiency and power management within a desired range.
Implementation Method 1
The primary winding coil 13 and the secondary winding coil 14 interact with the magnetic core assembly 11 to achieve the purpose of voltage regulation
Implementation Method 2
As a consequence, there is less magnetic flux leakage generated from the primary winding coil 13 and the secondary winding coil 14
Data Source
AI summary
A transformer having adjustable leakage inductance includes a primary winding coil, a secondary winding coil, a bobbin and a magnetic core assembly. The bobbin includes a winding section for winding the primary winding coil and the secondary winding coil thereon, wherein the bobbin further includes a channel therein. The magnetic core assembly is partially embedded into the channel of the first bobbin. The primary winding coil and the secondary winding coil are partially overlapped with each other and wound around the winding section of the bobbin to be defined as an overlap region. The region where the primary winding coil and the secondary winding coil are not overlapped with each other is defined as a non-overlap region. The leakage inductance of the transformer is adjusted according to an overlap ratio of the overlap region to the sum of the overlap region and the non-overlap region.