Transformer Former Thick Portion Winding Alignment
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Solution Overview
Problem
Existing electronic components, such as transformers, face issues with winding misalignment and increased leakage inductance due to variations in separation tape width and mispositioning, which can lead to weaving of windings despite the use of separation tapes.
Innovation Solution
The design incorporates thick portions at the ends of a cylindrical former, which serve as retaining structures for the coil windings, eliminating the need for separation tapes and ensuring proper alignment, thereby reducing leakage inductance and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separation tapes are used to ensure creepage distance and alignment, then the creepage distance between windings and terminals is ensured, but the manufacturing precision deteriorates due to width variations and mispositioning of tapes
Solution Approach 1:
The patent removes the separation tape component entirely and replaces it with an integrated thick portion structure formed directly on the former. This extraction of the problematic tape element eliminates width variations and mispositioning issues while maintaining the necessary creepage distance through the built-in thick portion design.
Solution Approach 2:
The patent merges the alignment function previously performed by separate tapes into the former structure itself through the thick portion. The thick portion is formed integrally with the former, combining the support structure and alignment reference into a single unified component, thereby eliminating misalignment between separate elements.
2Manufacturing precision
If separation tapes are used to align turns, then the alignment of turns is improved, but the leakage inductance increases due to weaving of windings
Solution Approach 1:
The patent extracts and removes the separation tape that causes winding weaving, replacing it with a smooth thick portion structure that provides turn alignment without introducing the harmful weaving effect. The thick portion is formed integrally with the former, providing a stable reference surface that prevents wire deviation during winding.
3Manufacturing precision
If separation tapes are used for alignment, then the alignment function is provided, but the device complexity increases due to additional components and assembly steps
Solution Approach 1:
The patent combines the alignment function into the former structure itself through the thick portion, eliminating the need for separate separation tape components. The thick portion is formed as an integral part of the former during the former manufacturing process, reducing the total component count and simplifying assembly operations.
Solution Approach 2:
The thick portion serves multiple functions simultaneously: it provides the alignment reference for winding turns, maintains the creepage distance, and supports the winding structure. This multi-functionality consolidates what would otherwise require multiple separate components into a single integrated feature.
Data Source
AI summary
According to one embodiment, an electronic component includes a cylindrical former proper, a thick portion provided at the end of the former proper and projecting from the outer surface of the former proper, a connecting portion adjacent to the thick portion including a terminal assembly, and a wire wound around the former proper and electrically connected to the terminal assembly. The thick portion includes a first retaining portion in which the wire running from the terminal assembly to the former proper is retained.