Flat-Plate LDC Transformer With Dual Secondary Coils
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Solution Overview
Problem
Conventional transformers for low voltage DC-DC converters (LDC) in electric vehicles are large in size, require numerous assembly processes, and suffer from inefficiencies and electromagnetic interference (EMI) due to poor alignment and insulation issues.
Innovation Solution
A compact transformer design for LDC in electric vehicles, featuring a flat plate type primary coil made of adhesion type covered conductive wire, with lower and upper secondary coils positioned under and above the primary coil respectively, to enhance insulation and reduce losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a specially designed bobbin and separate insulation casing are used for the primary coil, then insulation between primary and secondary coils is improved, but the size of the transformer increases
Solution Approach 1:
The patent combines the bobbin and insulation casing into a single integrated structure. The bobbin serves dual functions as both the winding support and the insulation barrier between primary and secondary coils, eliminating the need for a separate double casing while maintaining insulation reliability and reducing overall transformer size.
Solution Approach 2:
The bobbin is designed to perform multiple functions simultaneously: it provides mechanical support for winding the primary coil, maintains the geometric shape during assembly, and acts as the insulation barrier between primary and secondary coils. This multi-functional design eliminates redundant components and reduces transformer size.
2Stability of the object's composition
If multiple assembly processes including fixing members and separate casing insertion are used, then structural stability is improved, but productivity decreases
Solution Approach 1:
The patent integrates the bobbin and insulation casing into one component, reducing the number of assembly steps. Instead of separately inserting the primary coil into a casing and then inserting the secondary coil into another casing, the integrated bobbin-casing structure is placed directly, significantly simplifying the assembly process while maintaining structural stability.
Solution Approach 2:
The transformer is divided into distinct functional modules: the integrated bobbin-casing unit, the primary coil, and the secondary coil. This modular segmentation allows for pre-assembly of the bobbin-casing structure and independent preparation of coils, enabling parallel manufacturing processes that improve overall productivity.
3Ease of manufacture
If manual winding of the primary coil is performed, then flexibility in manufacturing is improved, but alignment precision and efficiency deteriorate
Solution Approach 1:
The bobbin is pre-designed with built-in alignment features such as positioning protrusions and grooves that guide the primary coil during winding. This preliminary preparation of the bobbin structure ensures that even during manual or automated winding, the coil maintains precise alignment and uniform winding density, eliminating alignment issues that would otherwise require complex post-winding adjustments.
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 solution enables efficient conversion of large current and high voltage while reducing the size and assembly complexity of the transformer, improving efficiency, EMI shielding, and product competitiveness.
Implementation Method 1
an LDC transformer for converting the AC voltage of the converter into a low voltage and insulating the AC voltage from the high-voltage battery
Implementation Method 2
the primary coil is formed of an adhesion type covered conductive wire made by covering an insulating tape as an outer covering on a conductive wire
Data Source
AI summary
Provided relates to a transformer for a low voltage DC-DC converter (LDC) of an electric vehicle, the transformer including: a flat plate type primary coil for receiving current from a high-voltage battery of the electric vehicle; a lower secondary coil element located under the primary coil in such a way as to come into close contact with an underside of the primary coil and generate induced current by means of the current flowing to the primary coil to supply the generated induced current to electronic components of the electric vehicle; and an upper secondary coil element located above the primary coil in such a way as to come into close contact with a top of the primary coil and generate induced current by means of the current flowing to the primary coil to supply the generated induced current to the electronic components of the electric vehicle.