Power Adaptor Transformer Nesting for Heat Dissipation
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Solution Overview
Problem
Traditional power adaptors face limitations in miniaturization due to wasted space and manual assembly requirements, which hinder automated production and heat dissipation, especially with discrete plug-in elements and wire-wound transformers.
Innovation Solution
A power adaptor design featuring a main electric unit, a transformer unit configured on the outer side for improved heat dissipation, and a bus capacitor unit positioned within a containing space formed between these units, utilizing a flat transformer and automated assembly methods to reduce manual labor and optimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete plug-in elements are assembled on a printed circuit board, then the power adaptor can be manufactured with traditional methods, but space is wasted due to different heights and shapes of elements, limiting miniaturization
Solution Approach 1:
The patent merges multiple discrete plug-in elements into an integrated transformer unit with pre-mounted components. The transformer unit integrates the transformer, bus capacitors, and other elements into a single compact module, eliminating the need for separate mounting on the printed circuit board and reducing overall space occupation.
Solution Approach 2:
The patent employs nesting by placing the bus capacitor unit within the containing space formed by the main electric unit and transformer unit. This nested arrangement allows efficient space utilization by fitting components into available voids and contours, minimizing the overall power adaptor volume.
2Ease of manufacture
If discrete plug-in elements are used, then traditional assembly is possible, but much manual work is required which is disadvantageous for automated production
Solution Approach 1:
The transformer unit combines multiple components into a single integrated module that can be mounted as one unit on the printed circuit board. This reduction in component count directly decreases manual assembly operations and enables automated production lines to handle fewer, larger components more efficiently.
Solution Approach 2:
The transformer unit is pre-assembled with bus capacitors and other elements mounted beforehand in a controlled manufacturing environment. This preliminary assembly allows for automated or semi-automated production of the transformer unit itself, which then becomes a ready-to-install module, reducing manual work at the final assembly stage.
3Ease of manufacture
If the transformer is located at the center of the power adaptor, then assembly is simplified, but heat dissipation is hindered
Solution Approach 1:
The patent extracts the transformer from the central location and repositions it to the outer side of the power adaptor. This relocation places the heat-generating component in a position with better thermal access to the external environment, improving heat dissipation while the containing space structure maintains assembly simplicity.
4Ease of manufacture
If a wire-wound transformer is used, then traditional assembly is possible, but manual work is required to complete assembly which is disadvantageous for automated production
Solution Approach 1:
The wire-wound transformer is merged with bus capacitors and other elements into a single transformer unit assembly. This integration reduces the number of separate manual operations required, as the entire unit can be handled and mounted as one component, facilitating transition to automated production systems.
Data Source
AI summary
A power adaptor includes a main electric unit, a transformer unit and a bus capacitor unit. The main electric unit is disposed on a first surface. The transformer unit is configured on the main electric unit and disposed on a second surface. The first surface is perpendicular to the second surface. The main electric unit and the transformer unit form a containing space. The bus capacitor unit includes at least one bus capacitor. The bus capacitor unit is disposed in the containing space.