Magnetic Component Terminal Integration for Leakage Reduction
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Solution Overview
Problem
Conventional magnetic components face challenges in reducing volume and power loss due to partition plate-induced leakage inductance, which limits their efficiency and current density output, especially at high altitudes.
Innovation Solution
The magnetic component design positions at least one outlet terminal of the primary winding and one or more outlet terminals of the secondary winding on the same side, using a bobbin with a channel and pin holders to reduce the need for a partition plate and minimize leakage inductance, allowing for increased current density and efficiency without increasing the component's volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a partition plate is used to separate primary and secondary sides, then safety requirements are met, but leakage inductance increases causing power loss
Solution Approach 1:
The patent positions outlet terminals of both primary and secondary windings on the same side of the magnetic component, changing the spatial arrangement from traditional opposite-side configuration. This dimensional repositioning allows terminal integration without requiring a thick partition plate, thereby reducing leakage inductance while maintaining safety isolation between windings.
2Loss of energy
If thicker thread diameter or parallel wound method is used, then leakage inductance decreases, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extracts the outlet terminals from their traditional positions at opposite ends of the windings and repositions them to the same side. This extraction and repositioning allows the terminals to be integrated into a common terminal block or mounting structure, simplifying the overall device structure and reducing complexity while achieving lower leakage inductance.
3Ease of manufacture
If conventional terminal positioning is used, then manufacturing is simpler, but component volume is larger and current density output is limited
Solution Approach 1:
The patent merges the outlet terminals of primary and secondary windings into a common terminal region on the same side. This merging allows for compact terminal block integration and reduces the overall component footprint. The combined terminal arrangement enables higher current density output while maintaining ease of manufacturing through standardized terminal mounting procedures.
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 effectively decreases the volume of the magnetic component while maintaining conversion efficiency and meeting safety requirements, even at high altitudes, by reducing power loss and allowing for higher power output without the need for additional layout area.
Implementation Method 1
A transformer is a magnetic component capable of Electro-Magnetic Energy Conversion for adjusting the voltage into a suitable range
Data Source
AI summary
The present invention discloses a magnetic component and which includes a bobbin, a magnetic core assembly, a first winding, and a second winding. The bobbin has a main body, a channel, and a pin holder. The main body has a primary winding section and a secondary winding section. The channel penetrates the main body. The pin holder is extended from a side of the main body. The magnetic core assembly is partially disposed in the channel of the bobbin. The first winding and the second winding respectively have two outlet terminals. The first winding is wound around the primary winding section. The second winding is wound around the secondary winding section. Two outlet terminals of the first winding and two outlet terminals of the second winding are configured in the pin holder.