Hollow Bobbin with Radial Protrusions for Transformer Winding Space
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Solution Overview
Problem
Traditional transformers have a reduced winding space due to thick blades separating the primary and secondary coils, making assembly difficult and inefficient.
Innovation Solution
A combined structure of a hollow bobbin with positioning structures and conductive sheets featuring engaging structures, allowing the conductive sheets to be securely fitted on the bobbin without additional blades, creating a space for direct winding and facilitating easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick blades are used to separate the primary coil and secondary coil, then the electrical insulation and structural support are improved, but the winding space is reduced and the device complexity increases
Solution Approach 1:
The patent merges the blade structure with the bobbin by forming protrusions directly on the bobbin surface that serve both as separation elements and as part of the winding support structure. This integration eliminates the need for separate thick blades while maintaining electrical insulation and structural support functions.
Solution Approach 2:
The patent utilizes the radial dimension of the bobbin by forming protrusions that extend radially outward from the bobbin surface. This creates separation between coils in the radial direction without requiring axial thickness, thereby preserving winding space while achieving electrical insulation.
2Strength
If thick blades are used to separate the primary coil and secondary coil, then the structural support is improved, but the assembly difficulty increases
Solution Approach 1:
The blade structure is merged with the bobbin into a single integrated component. The protrusions are formed directly on the bobbin surface, eliminating the need for separate blade assemblies and simplifying the overall structure while maintaining structural support strength.
Solution Approach 2:
The bobbin surface is segmented into multiple protrusions that are distributed around the circumference. This segmentation provides structural support at multiple points without requiring a single complex blade structure, thereby simplifying assembly while maintaining strength.
3Reliability
If blades are placed between the primary coil and secondary coil, then the electrical insulation is improved, but the space available for winding is reduced
Solution Approach 1:
The patent shifts the insulation function from the axial dimension (thick blades) to the radial dimension (protrusions on the bobbin surface). This allows electrical insulation to be achieved without consuming axial space that would be needed for winding operations, thereby improving winding efficiency.
Solution Approach 2:
The protrusions are formed as thin radial extensions from the bobbin surface rather than as thick axial blades. This thin-film approach provides sufficient electrical insulation while minimizing the space occupied, allowing more efficient use of the winding area.
Data Source
AI summary
A combined structure of hollow bobbin and conductive sheet for a transformer includes a hollow bobbin and at least one conductive sheet. The hollow bobbin includes an outer surface and at least one positioning structure formed on the outer surface. The conductive sheet is fit on the outer surface of the hollow bobbin and includes a main body and at least one engaging structure. The main body has a hollow portion, making the main body to have an inner circumference. The engaging structure is formed on the inner circumference of the main body and is engaged with the positioning structure of the hollow bobbin. The transformer includes at least one winding disposed on the outer surface of the hollow bobbin and abutting against the conductive sheet.