Layered Transformer Winding Layout for Low Leakage Inductance
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Solution Overview
Problem
Conventional transformers with multi-winding designs have high leakage inductance, complex manufacturing processes, and unstable product characteristics, leading to high labor costs, low industrial automation performance, and poor voltage cross regulation.
Innovation Solution
The transformer design features two first windings disposed between each other and the outer periphery of a bobbin, with a second winding stacked between them, allowing for a sequential arrangement that reduces leakage inductance and facilitates automation, while the second winding is connected in parallel with a second circuit board for enhanced voltage cross regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If windings are arranged irregularly around the magnetic core, then the transformer can accommodate multi-winding designs, but the leakage inductance increases and voltage cross regulation deteriorates
Solution Approach 1:
The transformer windings are segmented into distinct layers: a first layer with first windings and a second layer with second windings. This segmentation allows each winding to be positioned in an optimized location, reducing leakage inductance while maintaining multi-winding functionality. The layered structure enables better magnetic coupling between windings compared to irregular arrangements.
Solution Approach 2:
The patent transitions from a two-dimensional irregular arrangement of windings around the magnetic core to a three-dimensional layered structure. By stacking windings in multiple layers along the magnetic core, the design achieves improved voltage cross regulation and reduced leakage inductance while accommodating multiple windings in a compact space.
2Adaptability or versatility
If windings are arranged irregularly around the magnetic core, then multi-winding design is achieved, but the manufacturing process becomes complex and cannot be automated
Solution Approach 1:
The manufacturing process is segmented into standardized steps: placing windings in the first layer, placing windings in the second layer, and assembling the magnetic core. This segmentation transforms the complex irregular arrangement into a systematic, repeatable process that can be easily automated while maintaining multi-winding design flexibility.
Solution Approach 2:
Windings are pre-arranged in specific layers before final assembly with the magnetic core. This preliminary organization of windings in standardized layers simplifies the overall manufacturing process, making it suitable for automation while achieving the desired multi-winding configuration.
3Adaptability or versatility
If windings are arranged irregularly around the magnetic core, then multi-winding design is achieved, but product characteristics and dimensions become unstable
Solution Approach 1:
The winding structure is segmented into standardized layers with defined positions and orientations. This segmentation ensures that each winding occupies a precise location, resulting in stable product characteristics and dimensions. The layered approach eliminates the variability inherent in irregular arrangements while preserving multi-winding functionality.
Solution Approach 2:
The patent standardizes key parameters such as winding layer positions, winding orientations, and spacing between layers. By controlling these parameters systematically, the design achieves stable product characteristics and dimensions across production batches while maintaining the flexibility of multi-winding configurations.
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 significantly reduces leakage inductance, simplifies the manufacturing process, stabilizes product quality and dimensions, and improves voltage cross regulation, enabling easier automation and increased product commonality with a smaller volume.
Implementation Method 1
The transformer includes a magnetic core assembly, a bobbin, two first windings, a second winding and a second circuit board. The magnetic core assembly includes a first magnetic core and a second magnetic core.
Data Source
AI summary
A transformer includes a magnetic core assembly, a bobbin, two first windings, a second winding and a second circuit board. A bobbin channel runs through two opposite sides of the bobbin main body. The winding portion is formed on an outer periphery surface of the bobbin main body. The two first windings are disposed around the winding portion. One of the two first windings is disposed between the other one of the two first windings and the outer periphery surface of the bobbin main body. The second winding is disposed around the winding portion and disposed between the two first windings. The second circuit board hole and the bobbin channel are in communication with each other. The magnetic core assembly partially penetrates through the bobbin channel and the second circuit board hole. The second winding and the second circuit board are connected with each other in parallel.