Magnetic Device Bobbin Structure for Heat Dissipation and Inductance Stability
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Solution Overview
Problem
Conventional transformers face issues with increased weight due to high thermal conductivity resins used for heat dissipation, bending of outer bobbins under winding pressure, and variations in winding thickness leading to unstable leakage inductance.
Innovation Solution
A magnetic device with a bobbin structure featuring multiple bobbin members and gaps to maintain contact with the winding, allowing for effective heat dissipation without resin molding, reducing weight and stabilizing leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high thermal conductivity resin is used for heat dissipation, then heat dissipation performance is improved, but device weight increases
Solution Approach 1:
The patent removes the high thermal conductivity resin molding from the conventional transformer structure. Instead of using resin for both insulation and heat dissipation, the invention extracts the resin molding function and replaces it with a bobbin structure that provides heat dissipation through direct thermal contact between windings and the bobbin, eliminating the weight penalty of heavy resin while maintaining heat dissipation performance
Solution Approach 2:
The bobbin serves as an intermediary thermal conduction path between the windings and the external environment. The bobbin is positioned to make direct contact with the windings, acting as a heat sink that conducts heat away from the windings without requiring heavy resin molding, thus mediating the heat transfer function while reducing overall device weight
2Strength
If outer bobbin is used to support windings, then structural support is improved, but bobbin bending occurs under winding pressure
Solution Approach 1:
The outer bobbin is divided into multiple separate bobbin members instead of being a single continuous structure. This segmentation allows each individual bobbin member to independently support specific sections of the windings, distributing the mechanical stress and preventing bending that would occur in a continuous outer bobbin under winding pressure
Solution Approach 2:
The bobbin members are positioned at different locations and orientations to provide support from multiple dimensions. Rather than relying on a single outer bobbin structure, the invention uses strategically placed bobbin members that support the windings from various positions, creating a distributed support system that maintains shape stability under pressure
3Ease of manufacture
If winding thickness varies, then manufacturing flexibility is improved, but leakage inductance becomes unstable
Solution Approach 1:
The bobbin members are strategically positioned to provide localized support at critical sections where winding thickness variations would most affect leakage inductance. By concentrating support at these specific locations rather than uniformly across all windings, the invention maintains leakage inductance stability while allowing manufacturing flexibility in winding thickness
Solution Approach 2:
The invention changes the structural parameters of the bobbin from a continuous outer structure to discrete segmented members with specific positioning. This parameter change allows the system to accommodate variations in winding thickness while maintaining consistent electrical characteristics, as the bobbin members can be positioned to compensate for thickness variations and maintain stable magnetic coupling
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 effectively reduces the temperature rise of windings, prevents bobbin bending, and maintains stable leakage inductance across varying winding thicknesses, enhancing the overall performance and reliability of power conversion devices.
Implementation Method 1
a gap existing between each two adjacent of the insulators in a winding direction of the winding
Data Source
AI summary
A magnetic device includes a winding, and insulators by which the winding is surrounded. Each of the insulators is in contact with the winding. A gap exists between each two adjacent of the insulators in a winding direction of the winding.