Bobbinless Magnetic Component Design for Transformer Efficiency
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Solution Overview
Problem
Conventional transformers have limited winding space and efficiency due to the presence of a bobbin, which also increases material costs and hinders volume reduction and design flexibility.
Innovation Solution
A bobbinless magnetic component design where winding coils are directly wound around a magnetic core assembly with a fastening set, allowing for increased winding space, improved efficiency, reduced material costs, and compact volume, facilitated by the elimination of the bobbin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a bobbin is used to wind the primary and secondary coils, then the structural stability is improved, but the winding space is limited and the volume is increased
Solution Approach 1:
The patent removes the bobbin from the transformer structure entirely, extracting this non-essential component to reduce volume. The winding coils are directly wound around the magnetic core assembly without requiring a separate bobbin structure, thereby eliminating the volume occupied by the bobbin while maintaining structural integrity through direct mounting on the magnetic core.
Solution Approach 2:
The patent merges the functions of the bobbin and the magnetic core assembly by directly mounting the winding coils on the magnetic core. This consolidation eliminates the need for a separate bobbin structure, reducing the overall component volume while maintaining the necessary structural support for the windings.
2Strength
If a bobbin with wall thickness is used, then the mechanical strength is improved, but the winding space is reduced
Solution Approach 1:
The patent extracts and removes the bobbin structure entirely, eliminating the wall thickness that consumes valuable winding space. The winding coils are directly mounted on the magnetic core assembly, allowing the full available area to be utilized for winding without the reduction caused by bobbin wall thickness.
3Ease of manufacture
If a bobbin is used for winding coils, then the ease of winding is improved, but the material cost is increased
Solution Approach 1:
The patent removes the bobbin component entirely, eliminating the material cost associated with manufacturing and assembling this separate part. The winding coils are directly mounted on the magnetic core assembly, reducing the total material quantity required while maintaining manufacturability through simplified construction.
4Reliability
If a bobbin is used to separate primary and secondary coils, then the insulation is improved, but the device complexity is increased
Solution Approach 1:
The patent extracts and removes the bobbin structure used for separating and insulating primary and secondary coils. Instead, the patent relies on the inherent insulation properties of the magnetic core assembly and proper winding techniques to achieve the necessary electrical isolation, thereby reducing device complexity while maintaining insulation reliability.
Solution Approach 2:
The patent merges the insulation function into the overall winding and mounting process rather than requiring a separate bobbin structure. The magnetic core assembly serves as the mounting structure, and insulation is achieved through winding techniques and spacing, simplifying the overall device structure.
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
The bobbinless design enhances winding space and efficiency, reduces material costs, and simplifies assembly, enabling more compact and efficient magnetic components.
Implementation Method 1
Voltage regulation is performed by the electromagnetic induction effect among the magnetic core assembly 11, the primary winding coil 13 and the secondary winding coil 14 of the transformer 1
Data Source
AI summary
A magnetic component is disclosed. The magnetic component includes a magnetic core assembly, a fastening element, a first winding set and a second winding set. The magnetic core assembly includes at least a pillar. The fastening element is provided on an outer peripheral surface of the pillar. The first winding set is disposed around the outer peripheral surface of the pillar. The second winding set is disposed around the outer peripheral surface of the pillar and engaged with the fastening set. The first winding set and the second winding set are located adjacent to each other and disposed around the outer peripheral surface of the pillar.