Bobbin Extension Parts for Magnetic Element Terminal Distribution
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Solution Overview
Problem
Conventional magnetic elements face challenges in efficiently distributing terminals of the winding assembly, leading to crowded windows in the magnetic core assembly, increased layout space, and high fabricating costs due to the need for multiple magnetic elements to accommodate thicker second terminals, which complicates assembly and heat dissipation.
Innovation Solution
A bobbin design with a winding part and separate extension parts for first and second terminals, allowing for simultaneous fixation of terminals on these extensions, which are protruded out of the magnetic core assembly windows, ensuring proper spacing and distribution, thus enhancing window utilization and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If thicker conducting wires are used in the second winding assembly to handle higher current, then the current-carrying capacity is improved, but the terminals become crowded in the magnetic core assembly window and assembly difficulty increases
Solution Approach 1:
The patent extends the bobbin structure outward from the magnetic core assembly window to create additional terminal distribution space. Instead of confining all terminals within the window area, the extension parts provide a new spatial dimension for terminal arrangement, allowing thicker terminals to be properly spaced and connected without crowding the window region.
2Area of stationary object
If the dimension of the magnetic core assembly window is increased to accommodate more terminals, then the terminal distribution capability is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The bobbin is segmented into distinct parts: the main body and the extension parts. This segmentation allows the magnetic core assembly to maintain its standard window dimensions while the bobbin's extension parts provide the additional space needed for terminal distribution. The manufacturing process is simplified because the magnetic core assembly itself does not need to be customized, only the bobbin structure is modified.
3Adaptability or versatility
If multiple magnetic elements are employed to distribute the second terminals, then the terminal distribution capability is improved, but the layout space occupation and fabricating cost increase
Solution Approach 1:
The extension parts of the bobbin serve multiple functions: they provide mechanical support for terminal connections, ensure proper spacing between terminals, facilitate heat dissipation, and maintain safety clearance. This multi-functional design allows a single magnetic element to handle the distribution of multiple terminals without requiring additional magnetic elements, thereby reducing layout space occupation.
4Area of stationary object
If terminals are densely arranged in the magnetic core assembly window, then the space utilization is improved, but the heat dissipation capability deteriorates
Solution Approach 1:
The patent extracts the terminal connection function from the magnetic core assembly window by providing extension parts of the bobbin that extend outward. This separation allows the window to be optimized for its primary function of accommodating the magnetic core and winding, while the extension parts provide a dedicated region for terminal connections with adequate spacing for heat dissipation.
Data Source
AI summary
A magnetic element includes a bobbin, a first winding assembly, a second winding assembly and a magnetic core assembly. The bobbin includes a winding part, a first extension part and a second extension part. The first extension part and the second extension part are separated from each other by the winding part. The first winding assembly is wound around the winding part of the bobbin, and includes plural first terminals. The second winding assembly is wound around the winding part of the bobbin, and includes plural second terminals. The magnetic core assembly includes a first window and a second window. The first extension part is protruded out of the first window. The second extension part is protruded out of the second window. At least one of the first terminals and at least one of the second terminals are simultaneously fixed on the first extension part and/or the second extension part.