PCB-Assisted Primary Coil Assembly for Low-Noise Transformer Winding
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Solution Overview
Problem
Transformers face inefficiencies in assembly, noise generation due to vibration, and compromised electromagnetic interference (EMI) characteristics due to inconsistent inner and outer sizes of main and auxiliary windings, particularly when the primary coil is composed of bonding coils or multilayer PCBs, leading to increased costs and design challenges.
Innovation Solution
A primary coil assembly featuring a bonding coil with auxiliary windings formed using flexible or hard printed circuit boards (PCBs) on both surfaces, allowing for improved terminal connections and winding patterns that minimize noise and maintain EMI characteristics, enabling efficient assembly and operation across various capacity electronic appliances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the primary coil is composed of bonding coils or multilayer PCBs, then the transformer can be manufactured with simpler structure, but the inner and outer sizes become inconsistent causing noise and vibration
Solution Approach 1:
The patent applies local quality by creating an asymmetric structure where the outer size of the primary coil assembly is designed to be larger than the inner size, specifically adding a protrusion portion that extends beyond the bobbin's outer peripheral surface. This localized dimensional adjustment ensures consistent outer dimensions while maintaining the simpler bonding coil or multilayer PCB construction, thereby preventing noise and vibration without requiring complex overall restructuring.
2Adaptability or versatility
If the primary coil is composed of bonding coils with both main winding and auxiliary winding, then the transformer can handle various capacity requirements, but inner and outer sizes are inconsistent causing tilting during assembly
Solution Approach 1:
The patent applies preliminary action by pre-forming a protrusion portion on the primary coil assembly that extends beyond the bobbin's outer peripheral surface before assembly. This pre-configured structural feature ensures proper positioning and prevents tilting during the assembly process, maintaining assembly stability while preserving the versatility of using bonding coils for various capacity requirements.
3Device complexity
If the primary coil uses only multilayer PCB, then the structure is simplified, but design diversification becomes difficult and cost increases with capacity
Solution Approach 1:
The patent applies segmentation by dividing the primary coil into two distinct parts: a main winding portion made of bonding coils that provides flexibility for design diversification and capacity adaptation, and an auxiliary winding portion made of multilayer PCB that maintains structural simplicity. This segmented approach allows the transformer to achieve both design versatility and cost-effectiveness by selectively using different construction methods for different functional requirements.
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 enhances assembling efficiency, reduces noise from vibration, and maintains designed EMI characteristics, supporting the use of transformers in both low and high-capacity electronic devices with a simplified structure.
Implementation Method 1
a primary coil assembly for a transformer and a transformer including the same... configured to perform electromagnetic mutual induction
Data Source
AI summary
The primary coil assembly, which includes a primary coil interposed between a pair of secondary coils and configured to perform electromagnetic mutual induction, and includes: a bonding coil having both ends connected to primary-side terminal pins of the transformer; a first PCB member provided on an upper surface of the bonding coil and configured to constitute an upper-side auxiliary winding of the primary coil; and a second PCB member provided on a lower surface of the bonding coil and configured to constitute a lower-side auxiliary winding of the primary coil.