Modular Transformer Bobbin Structure for High-Density Design

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Solution Overview

Problem

Conventional bobbin structures for transformers have limitations in high-density design, economic fabrication, and flexibility due to unique, non-interchangeable modular bobbin members, leading to reduced winding depth and increased fabrication costs, which hampers performance and competitiveness.

Innovation Solution

A modular bobbin structure with interconnected bobbin members featuring perforation channels, baffles, and connecting members that form insulating slots for winding coils, eliminating the need for an insulating sleeve, allowing for simpler construction and reduced size, enabling economic fabrication and improved performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulating sleeve is used to enclose the perforation channel in conventional bobbin structures, then insulation is provided, but winding depth is reduced and waste occurs

Engineering Contradiction:

ImproveinsulationVSAvoidwinding depth

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulating sleeve is completely removed from the bobbin structure. Instead, the bobbin body itself is designed with integrated insulation features where the bobbin material directly provides electrical insulation between the winding coil and magnetic core, eliminating the separate insulating sleeve component and recovering the lost winding depth.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The insulation function is merged into the bobbin body structure itself. The bobbin material and structure are designed to simultaneously provide mechanical support and electrical insulation, combining multiple functions into a single integrated component rather than using separate insulating sleeves.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If multiple unique bobbin member modules are used in conventional structures, then specific functional requirements are met, but fabrication cost increases and management complexity rises

Engineering Contradiction:

Improvefunctional requirementsVSAvoidfabrication cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single universal bobbin member design is created that can serve multiple positions and functions in the magnetic component assembly. This standardized bobbin member can be used in various configurations to meet different functional requirements, replacing the need for multiple unique bobbin member modules and enabling interchangeable use across different positions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The bobbin members are designed with homogeneous structure and material properties, using the same design and material throughout. This standardization simplifies manufacturing processes, reduces fabrication costs, and enables easier management and inventory control compared to multiple different bobbin member types.

Inventive Principle:

Principle #33Homogeneity

3Reliability

If conventional bobbin structures with insulating sleeves are used, then insulation is provided, but the structure size increases and high-density requirements are not met

Engineering Contradiction:

ImproveinsulationVSAvoidstructure size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The insulating sleeve is extracted and removed from the structure. The insulation function is provided directly by the bobbin body and winding coil arrangement, eliminating the extra volume occupied by the separate insulating sleeve and enabling more compact high-density designs.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The design utilizes thin film insulation layers integrated into the bobbin structure rather than thick insulating sleeves. This provides sufficient electrical insulation while occupying minimal space, enabling compact structures that meet high-density requirements.

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of manufacture

If modular bobbin members with connecting members are used, then assembly is simplified, but additional components are introduced

Engineering Contradiction:

ImproveassemblyVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The connecting function is merged into the bobbin member structure itself. The bobbin members incorporate integrated connection features such as protrusions or engagement structures that allow direct assembly with adjacent components, eliminating the need for separate connecting members and reducing overall component count.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8203415B2Bobbin structure and transformer having the same

Publication Date: 2012.06.19 DELTA ELECTRONICS INC(CN)

AI summary

A bobbin structure is disclosed. The bobbin structure comprises plural modular bobbin members each connected with each other. Each modular bobbin member comprises a perforation channel, a first baffle disposed on one end of the perforation channel and placed perpendicularly to the perforation channel, and a second baffle disposed on the other end of the perforation channel and placed oppositely to the first baffle. The first baffle has a first connecting member, and the second baffle has a second connecting member. A first winding slot is disposed between the first baffle and the second baffle. The bobbin structure is formed by the engagement between the first connecting member of one modular bobbin member and the second connecting member of another connected one, wherein a second winding slot is formed between two connected modular bobbin members.