Overmolded Planar Transformers for Low Leakage in Welding Power Supplies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high-frequency transformers used in welding-type power supplies suffer from leakage inductance, which reduces output, causes overheating, and is detrimental to transistor switching circuits.
Innovation Solution
The development of low-leakage overmolded planar transformers, which utilize stamped conductors insulated with molded insulators, stacked in a planar configuration with a magnetic core, to minimize leakage inductance and meet insulation standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-frequency transformers are used in welding-type power supplies, then voltage transformation and electrical isolation are achieved, but leakage inductance increases causing reduced output, overheating, and detrimental effects on transistor switching circuits
Solution Approach 1:
The patent transitions from conventional three-dimensional wound transformer geometry to a planar two-dimensional winding arrangement. The windings are formed as planar structures on a substrate, fundamentally changing the spatial dimension of the transformer construction. This dimensional change enables tighter coupling between primary and secondary windings, reducing leakage inductance while maintaining electrical isolation and voltage transformation functionality.
Solution Approach 2:
The patent combines multiple functions into integrated planar structures. The windings, insulation, and support structures are merged into a single planar assembly where the secondary winding is positioned in direct contact with the primary winding on the same substrate. This merging eliminates gaps and improves magnetic coupling, thereby reducing leakage inductance while maintaining electrical isolation through the insulating substrate.
2Productivity
If stamped conductors with molded insulators are used instead of conventional windings, then manufacturing labor efficiency and cost are improved, but insulation sufficiency may be compromised
Solution Approach 1:
The patent changes the material parameter of the substrate to具有高 dielectric strength and appropriate thickness to ensure sufficient insulation. By selecting materials with suitable electrical properties and optimizing the substrate thickness parameter, the design achieves both automated manufacturing compatibility and adequate electrical insulation between primary and secondary windings.
Solution Approach 2:
The patent uses composite construction where stamped conductive layers are combined with molded insulating substrate materials. This composite approach integrates the advantages of both materials: the precision and manufacturability of stamped conductors with the electrical insulation properties of molded polymers or ceramics, achieving both high productivity and reliable insulation.
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
These transformers are more labor-efficient and cost-effective to produce, while providing sufficient insulation and reduced leakage inductance, leading to improved performance and reliability in welding-type power supplies.
Implementation Method 1
a magnetic core that is magnetically coupled to the primary winding and the secondary winding
Data Source
AI summary
Disclosed example high-frequency transformers include: a primary winding; a first secondary winding comprising a first planar conductor and a molded insulator, the first secondary winding being stacked in contact with the primary winding; and a magnetic core that is magnetically coupled to the primary winding and the first secondary winding.