Asymmetric Transformer Core Alignment via Spring Fixing
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Solution Overview
Problem
The alignment issues between I-core and E-core in sheet-like transformers lead to increased magnetic flux leakage and transformation loss, potentially causing circuit damage due to magnetic saturation, especially in high-temperature environments.
Innovation Solution
A power converting transformer design where the I-core is larger than the E-core, with fixing grooves and recesses, and a fixing spring to secure them together, preventing misalignment and reducing magnetic flux leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the I-core and E-core are configured to have the same external dimension, then the transformer structure is simplified, but the alignment between cores becomes unstable leading to increased magnetic flux leakage
Solution Approach 1:
The patent applies asymmetry by making the I-core larger than the E-core in external dimensions. Specifically, the I-core has a width W1 and length L1, while the E-core has a width W2 and length L2, where W1 > W2 and L1 > L2. This asymmetric configuration ensures that even when misalignment occurs, the E-core remains positioned within the I-core's magnetic path, preventing magnetic flux leakage and maintaining reliable alignment stability.
2Loss of energy
If the I-core and E-core are pressed tightly together, then magnetic flux leakage is reduced, but the risk of circuit destruction due to magnetic saturation increases in high temperature regions
Solution Approach 1:
The patent applies local quality by introducing an air gap at specific locations in the magnetic path. The E-core includes a gap-forming portion that creates a controlled air gap between the E-core and I-core. This localized air gap increases magnetic reluctance in a specific region, preventing magnetic saturation while maintaining tight coupling elsewhere to minimize overall magnetic flux leakage and transformation loss.
3Reliability
If fixing structures are added to prevent misalignment, then alignment stability improves, but device complexity increases
Solution Approach 1:
The patent merges the alignment function into the core structures themselves rather than adding separate fixing mechanisms. The I-core includes positioning protrusions that fit into corresponding recesses on the E-core, and the asymmetric dimensional design inherently guides proper alignment. This integration of alignment functionality into the cores eliminates the need for additional fixing structures, maintaining reliability while avoiding increased device complexity.
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 effectively suppresses misalignment, reducing power loss and enhancing the reliability and efficiency of the transformer by maintaining stable electric characteristics.
Implementation Method 1
a fixing spring wrapped around the I-core and the E-core through the fixing grooves and the fixing recess portions
Implementation Method 2
a substantially rectangular flat I-core extending along an x-y plane in an xyz orthogonal coordinate system; and an E-core including a substantially rectangular flat base portion extending along the x-y plane, a central leg portion installed upright at a center of the base portion to extend in a z-direction
Data Source
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AI summary
In a power converting transformer, an I-core has a pair of fixing grooves provided at centers on opposite side surfaces of the I-core in a y-direction in an xyz orthogonal coordinate system, the fixing grooves extending through the I-core in the z-direction, and an E-core has a pair of fixing recess portions provided at x-direction centers of the y-direction opposite end portions of the base portion on a surface opposite from a surface of the base portion facing the I-core. The I-core and the E-core are pressed and fixed to each other by a fixing spring wrapped around the I-core and the E-core through the fixing grooves and the fixing recess portions. An x-direction length of the E-core is shorter than an x-direction length of the I-core, and a y-direction length of the E-core is shorter than or equal to a y-direction distance between the fixing grooves of the I-core.