High Voltage Transformer Space-Saving Primary Windings
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Solution Overview
Problem
Existing high-voltage transformers for discharge lamps face challenges in meeting both size restrictions and electrical requirements, particularly in efficiently utilizing space to accommodate both primary and secondary windings while maintaining high current conduction capabilities.
Innovation Solution
A high-voltage transformer design featuring an elongate ferromagnetic core with a plastic transformer frame containing segment walls perpendicular to the core, allowing the secondary winding to occupy the spaces between these walls, and using connection pins made of mechanically stable materials embedded in the plastic frame to form the primary winding, which are also used for mechanical and electrical connections, thereby optimizing space for the secondary winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If primary windings are formed by sheet metal conductors on a lead frame with insertion molding, then electrical connectivity is achieved, but substantial manufacturing complexity and cost are incurred
Solution Approach 1:
The patent extracts the primary winding conductor function from the complex lead frame structure and implements it using simple connection pins that are directly molded into the bobbin. This eliminates the need for separate lead frames and insertion molding processes, significantly simplifying manufacturing while maintaining electrical connectivity.
Solution Approach 2:
The connection pins serve multiple functions: they provide electrical connectivity for the primary winding, act as structural support elements, and eliminate the need for separate lead frame components. This multi-functionality reduces both manufacturing steps and overall device complexity.
2Area of stationary object
If primary windings use traditional lead frame configuration, then electrical connectivity is established, but excessive space is consumed reducing room for secondary winding
Solution Approach 1:
The patent removes the bulky lead frame structure and replaces it with compact connection pins integrated directly into the bobbin. This extraction of the unnecessary lead frame component frees up substantial space within the transformer assembly for accommodating the secondary winding.
Solution Approach 2:
The connection pins are nested directly within the bobbin structure during the molding process, eliminating the need for separate lead frame layers. This nesting approach optimizes space utilization by integrating the primary winding connection function within the existing bobbin volume rather than adding external lead frame structures.
3Area of stationary object
If connection pins are molded in segment walls, then space is saved for secondary winding, but mechanical stability must be maintained
Solution Approach 1:
The patent applies local quality by strategically positioning connection pins within specific segment walls of the bobbin where they provide both electrical connectivity and mechanical support. The pins are embedded in locations that optimize both space utilization for the secondary winding and structural integrity of the overall assembly.
Solution Approach 2:
The bobbin is constructed as a composite structure combining plastic material with embedded metallic connection pins. This composite approach allows the plastic to provide insulation and structural form while the metallic pins provide mechanical strength and electrical conductivity, maintaining overall mechanical stability while saving space.
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 design enables a compact transformer that can accommodate more turns or thicker conductors for the secondary winding, enhancing current conduction and voltage transformation efficiency while maintaining mechanical stability and electrical connectivity.
Implementation Method 1
a high-voltage transformer comprising a primary and a secondary winding... generating the high ignition voltage at the secondary winding
Implementation Method 2
An elongate core made out of a ferromagnetic material, preferably ferrite
Data Source
Figure 1~2
Figure 3~4
Figure 5a~6
AI summary
A high voltage transformer is described with an elongate core (38) out of a ferromagnetic material. A transformer frame (36) out of plastic material has segment walls (40) arranged perpendicular to the core (38). A secondary- winding is wound around the core (38) in winding segments divided by the segment walls (40). A primary winding is formed of conductor segments to provide a loop around the core. At least one of the conductor segments is a connection pin (50) molded in one of the segment walls.