High Voltage Transformer Coil Bobbin With Field-Control Electrodes
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Solution Overview
Problem
The existing high voltage transformer designs for X-ray systems face challenges in minimizing volume while maintaining high voltage isolation, as increasing operating frequency to reduce size is not feasible, requiring careful design to avoid unnecessary dimension increases and prevent saturation effects.
Innovation Solution
The design incorporates a coil bobbin placed inside a closed sleeve with neighboring sleeves attached at the outer perimeter, featuring a labyrinth-like structure in the joints and field-control electrodes to shape the electric field, reducing the thickness of plastic parts, and includes labyrinth seals and insulating spring washers to maximize surface distance and retain the high voltage winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the operating frequency is increased to reduce transformer size, then the transformer volume decreases, but saturation effects occur and high voltage isolation cannot be maintained
Solution Approach 1:
The coil bobbin is placed inside a closed sleeve, creating a nested structure where the high voltage winding is contained within the sleeve. This nesting approach maximizes the use of available space while maintaining proper insulation distances, allowing compact design without compromising high voltage isolation.
Solution Approach 2:
The invention uses a labyrinth-like structure in the joints connecting upper and lower halves of the sleeves, which extends the surface distance between high voltage and low voltage windings in a three-dimensional path rather than a straight line. This allows maintaining isolation requirements while reducing overall transformer dimensions.
2Reliability
If plastic holders and spacers are used between primary and secondary windings to maintain isolation, then high voltage isolation is ensured, but transformer volume increases
Solution Approach 1:
The invention removes all plastic holders and spacers between primary and secondary windings, eliminating unnecessary insulating components. Instead, it relies on the closed sleeve structure and labyrinth-like joints to provide the required high voltage isolation, thereby minimizing transformer volume.
Solution Approach 2:
The functional roles of mechanical support and electrical insulation are merged into the closed sleeve structure. The sleeve both mechanically retains the coil bobbin and provides high voltage isolation through its labyrinth-like joints, eliminating the need for separate plastic holders and spacers.
3Reliability
If the thickness of plastic parts is increased to improve insulation, then high voltage isolation is enhanced, but transformer volume and weight increase
Solution Approach 1:
The invention changes the geometric parameters of the sleeve joints to create a labyrinth-like structure that extends the insulation path length without increasing the thickness of plastic parts. This allows achieving required isolation levels while minimizing the weight and volume of insulating components.
Solution Approach 2:
The invention replaces thick plastic insulating parts with a thin-walled closed sleeve structure that achieves high voltage isolation through its labyrinth-like joint geometry rather than material thickness. This substitution significantly reduces the weight of insulating components while maintaining isolation performance.
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
This configuration minimizes transformer volume by eliminating plastic holders and spacers between windings, reducing the thickness of plastic parts, and effectively shapes the electric field to lower peak amplitude, thereby enhancing high voltage isolation without increasing dimensions.
Implementation Method 1
at least one field-control electrode, which is adapted to shape an electric field generated by the high voltage winding
Implementation Method 2
using a labyrinth-like structure in the joints connecting upper and lower halves of the sleeves to maximize the surface distance
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a high voltage transformer (50) comprising: a magnetic core (5); a low voltage winding (10); a high voltage winding (20); at least one inner sleeve (30); and a coil bobbin (24) for carrying the high voltage winding (20), wherein the coil bobbin (24) is configured to be arranged inside the at least one inner sleeve (30) and configured to be attached to the at least one inner sleeve (30) at an outer perimeter of the at least one inner sleeve (30); and wherein the coil bobbin (24) comprises at least one field-control electrode (22), which is adapted to shape an electric field generated by the high voltage winding (20).