Nested Bobbin Transformer Layout for Low Parasitic Capacitance
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Solution Overview
Problem
Existing transformer modules face challenges in minimizing parasitic capacitance and noise generation while maintaining compact size and high power conversion efficiency, particularly in electric vehicles where electromagnetic interference can cause malfunctions.
Innovation Solution
A transformer module design featuring a first bobbin unit for the primary coil and a second bobbin unit for the secondary coil, with specific side plates and partition units to minimize overlap and parasitic capacitance, and a core unit to guide and protect the coils, ensuring stable winding and efficient power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the primary coil and secondary coil areas are made to overlap partially to decrease parasitic capacitance, then parasitic capacitance is reduced and noise is minimized, but the winding stability and power conversion efficiency may be compromised
Solution Approach 1:
The transformer is divided into separate first and second bobbin units, each housing one coil. This segmentation allows the coils to be positioned with partial overlap of their wound areas, reducing parasitic capacitance while maintaining independent winding structures for stability.
Solution Approach 2:
The first bobbin unit is accommodated within the second bobbin unit, creating a nested configuration. This nesting enables the primary and secondary coil areas to partially overlap, achieving reduced parasitic capacitance while the containing bobbin structure maintains winding stability.
2Object-generated harmful factors
If the primary coil and secondary coil areas are made to overlap partially to decrease parasitic capacitance, then parasitic capacitance is reduced and noise is minimized, but the power conversion efficiency may be compromised
Solution Approach 1:
Separating the coils into distinct bobbin units with controlled spatial overlap reduces electromagnetic interference and noise while maintaining efficient magnetic coupling for power conversion.
Solution Approach 2:
The bobbin units serve as intermediary structures that enable optimal positioning of the coils. The partial overlap configuration mediated by the bobbins reduces noise through decreased parasitic capacitance while preserving power conversion efficiency.
3Area of stationary object
If a compact transformer structure is implemented to minimize the area occupied, then the transformer module size is reduced, but the winding stability and manufacturing complexity may increase
Solution Approach 1:
The nested configuration of the first bobbin unit within the second bobbin unit achieves a compact transformer module that minimizes occupied area while the structured nesting provides inherent support for stable winding and assembly.
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 design effectively reduces parasitic capacitance and noise, enhancing electrical stability and power conversion efficiency while maintaining a compact form factor suitable for high-voltage applications.
Implementation Method 1
a transformer module includes a first bobbin unit around which a primary coil is wound and a second bobbin unit around which a secondary coil is wound
Data Source
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AI summary
A transformer module may include a first bobbin unit around which a primary coil is wound and a second bobbin unit around which a secondary coil is wound and that accommodates at least a portion of the first bobbin unit.