Bobbin Pin Holder Design for Transformer Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional bobbins for transformers are inefficient in pin winding and welding due to the foil-shaped structure of copper pins, making the process time-consuming and inconvenient.

Innovation Solution

A bobbin design with a pin holder featuring locating holes on one of its plates, allowing for easier insertion and secure fastening of pins, which includes a detachable design with a skid rail and fastening structures to stabilize the pin holder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If pins are winded or welded on legs of conventional bobbin, then pins can be fastened, but the process wastes time and is inconvenient

Engineering Contradiction:

Improvepin fastening convenienceVSAvoidassembly time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

A pin holder is introduced as an intermediary component between the bobbin body and the pins. The pin holder includes locating holes that guide pin insertion and fastening structures that secure the pins, eliminating the need for time-consuming winding or welding operations directly on the bobbin legs.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bobbin is segmented into functional components: the bobbin body with legs, and a separate pin holder with fastening structures. This segmentation allows the pin holder to be specifically designed for efficient pin fastening, while the bobbin body maintains its structural function.

Inventive Principle:

Principle #1Segmentation

2Reliability

If copper foils are used as pins, then electrical connection is achieved, but the foil-shaped structure makes winding or welding more difficult

Engineering Contradiction:

Improveelectrical connectionVSAvoidpin fastening process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The pin holder provides localized support and positioning specifically at the pin insertion points through locating holes. This localized quality enhancement allows copper foil pins to be easily inserted and fastened without requiring complex winding or welding operations, while maintaining reliable electrical connection.

Inventive Principle:

Principle #3Local quality

3Ease of operation

If a pin holder with locating holes is added to the bobbin, then pin insertion is facilitated, but the device complexity increases

Engineering Contradiction:

Improvepin insertion easeVSAvoidbobbin structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The pin holder is merged with the bobbin body through fastening structures that attach the pin holder to the bobbin legs. This merging integrates the pin holding function into the existing bobbin structure, minimizing the increase in overall device complexity while maintaining the operational benefits.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9076582B2Magnetic component and bobbin thereof

Publication Date: 2015.07.07 DELTA ELECTRONICS INC(CN)

AI summary

A bobbin can be used for a magnetic component. The magnetic component includes at least one coil, and the coil includes at least one pin. The bobbin includes a body and a pin holder. The body includes a winding part and two plates. The winding part is used for winding the coil. The plates are respectively disposed on the opposites of the winding part. The pin holder is disposed on one of the plates, and it includes at least one locating hole for inserting the pin.