Transformer Bobbin Guide Wall Prevents Core Discharge
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Solution Overview
Problem
In transformers, the configuration where the primary winding's start side is adjacent to the secondary winding can lead to electric discharges due to proximity to the E-shaped core, and existing solutions that separate the primary winding from the core do not adequately prevent such discharges.
Innovation Solution
A transformer-bobbin design featuring a middle barrel portion with an insertion hole for the core, lower and upper flange portions that protrude away from the axis center, and a terminal bed unit with a slit and guide wall surface to guide the conductive wire, ensuring the primary winding's start terminal is separated from the core center-leg portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the winding start side of the primary winding is arranged adjacent to the secondary winding to improve space utilization, then the compactness of the transformer is improved, but electric discharge occurs between the primary winding and the E-shaped core
Solution Approach 1:
The patent introduces a guide wall surface as an intermediary structure between the primary winding and the E-shaped core. This guide wall surface, formed by the guide wall portion protruding from the lower flange, creates a physical barrier and increases the air gap distance, preventing electric discharge while allowing the winding start side to remain adjacent to the secondary winding for compact design.
Solution Approach 2:
The patent solves the proximity problem by utilizing the vertical dimension (height direction) rather than only the horizontal plane. The guide wall portion protrudes upward from the lower flange, creating a three-dimensional separation structure that increases the distance between the winding start side and the core in the vertical direction, thereby preventing discharge while maintaining horizontal compactness.
2Reliability
If the winding start side of the primary winding is positioned apart from the secondary winding by disposing it along the bottom side of the bobbin to prevent electric discharge, then the electrical insulation reliability is improved, but the distance between the winding start side and the E-shaped core becomes too small causing electric discharge
Solution Approach 1:
The patent transitions from two-dimensional planar separation to three-dimensional separation by introducing the guide wall portion that protrudes vertically from the lower flange. This creates additional separation distance in the height direction, effectively increasing the total distance between the winding start side and the E-shaped core center-leg portion beyond what horizontal displacement alone could achieve.
Solution Approach 2:
The guide wall surface is pre-formed as part of the bobbin structure before winding occurs. This preliminary structural feature ensures that when the winding start side is positioned along the bottom side of the bobbin, the guide wall already provides the necessary separation and protection from electric discharge to the E-shaped core.
Data Source
AI summary
A transformer-bobbin including a winding-frame portion constituted by a middle barrel portion 63, a lower flange portion 62 and an upper flange portion 61, wherein there is provided a slit portion 67 which notches the terminal bed unit 65 and the lower flange portion 62 and concurrently which extends in the centrally approaching and separating direction toward the middle barrel portion 63 side, and wherein at the slit portion 67, there is provided a guide wall surface 68a whose side on the middle barrel portion 63 side is positioned on the lower flange portion side compared with whose side apart from the middle barrel portion 63.