Planar OBC Transformer Layout for Insulation and EMI Reduction
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Solution Overview
Problem
Conventional transformers for on-board chargers (OBC) of electric vehicles are bulky, have complex assembly processes, leading to low productivity, and suffer from electromagnetic interference (EMI) due to misalignment of coils.
Innovation Solution
A transformer design featuring a flat primary coil made of adhesion-type insulating tape-covered conductive wire, with upper and lower secondary coils positioned to ensure close contact and alignment with the primary coil, reducing assembly complexity and improving insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If secondary coils are wound coaxially on the primary coil with insulating tapes applied repeatedly, then insulation is ensured, but the transformer size becomes bulky
Solution Approach 1:
The patent transitions from conventional coaxial winding (one-dimensional radial arrangement) to a planar arrangement where secondary coils are positioned adjacent to the primary coil in the same plane. This dimensional change eliminates the need for repeated insulating tapes and reduces overall transformer volume while maintaining insulation performance through direct planar contact.
Solution Approach 2:
The patent merges the primary and secondary coils into a single planar structure where they are wound together in the same plane. This integration eliminates the need for separate insulating tape applications between layers, reducing both the number of assembly steps and the overall transformer size while maintaining electrical insulation through the winding structure itself.
2Reliability
If insulating tapes are applied repeatedly to primary and secondary coils during winding, then insulation is achieved, but the number of assembly processes increases
Solution Approach 1:
The patent combines the winding of primary and secondary coils into a single integrated process in the same plane, eliminating the need for repeated insulating tape applications. This merging of winding operations reduces the number of assembly steps from multiple insulation applications to a single continuous winding process, significantly improving productivity.
Solution Approach 2:
The patent extracts and eliminates the insulating tape application steps from the assembly process by adopting a planar winding configuration. By removing these intermediate insulation steps, the assembly process is simplified from multiple sequential operations to a more streamlined single-plane winding operation.
3Ease of manufacture
If primary and secondary coils are wound manually, then flexibility in winding is maintained, but coil alignment deteriorates causing EMI losses
Solution Approach 1:
The patent transitions from three-dimensional coaxial winding to two-dimensional planar winding, where coils are arranged in the same plane. This dimensional change enables better alignment control and reduces gaps between coils, minimizing electromagnetic interference and energy losses while maintaining manufacturing flexibility through the simplified planar configuration.
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 achieves improved insulation at high voltages, enhanced efficiency, reduced EMI, and a smaller size, increasing productivity and competitiveness of the OBC.
Implementation Method 1
a bonding layer formed by applying an adhesive onto an outer peripheral surface of the insulating tape
Implementation Method 2
a transformer for converting the high-frequency AC voltage of the second converter into a higher voltage and physically insulating the 220V AC from the high-voltage battery
Data Source
AI summary
Provided relates to a transformer for an on-board charger (OBC) of an electric vehicle, the transformer including: a flat primary coil for receiving current from an electric vehicle charger; a lower secondary coil element located under the primary coil in such a way as to come into close contact with an underside of the primary coil and generate induced current by means of magnetic induction of the current flowing to the primary coil to supply the generated induced current to a high-voltage battery; and an upper secondary coil element located above the primary coil in such a way as to come into close contact with a top of the primary coil and generate induced current by means of magnetic induction of the current flowing to the primary coil to supply the generated induced current to the high-voltage battery.