Pulse Transformer Drum Core Terminal Electrode Segmentation
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Solution Overview
Problem
Conventional surface-mount pulse transformers face challenges in accurately winding wires and connecting them to terminal electrodes without wire lead sections contacting different terminal electrodes, making it difficult to handle with automatic winding machines.
Innovation Solution
The design includes a drum core with specific terminal electrode and center tap configurations on each flange, where wires are wound and connected in a manner that avoids crossing with other wires, allowing for reliable connection and easy handling with automatic machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are led out from side surfaces to cross the center axis for connection, then connection to terminal electrodes is achieved, but wire lead sections may contact different terminal electrodes causing connection errors
Solution Approach 1:
The terminal electrodes are segmented into two groups: those on the inner side surface and those on the outer side surface. Wires connected to inner side terminal electrodes are led out from the inner side, while wires connected to outer side terminal electrodes are led out from the outer side. This segmentation prevents wire lead sections from contacting wrong terminal electrodes, improving connection reliability while maintaining ease of handling.
2Volume of moving object
If terminal electrodes are positioned close to inner side surface for compact design, then device size is reduced, but wire lead sections may contact incorrect terminal electrodes
Solution Approach 1:
Different regions of the terminal electrodes have different functions. Terminal electrodes on the inner side surface are designed to be connected from the inner side, while those on the outer side surface are designed to be connected from the outer side. This local differentiation in connection approach ensures that even when terminal electrodes are positioned close together for compact design, wires cannot contact incorrect terminals, thus maintaining connection reliability.
3Adaptability or versatility
If wires cross the center axis for connection, then connection flexibility is improved, but automatic winding machine handling becomes difficult
Solution Approach 1:
The connection path is segmented into two distinct routes: wires for inner side terminal electrodes are led out from the inner side surface without crossing the center axis, while wires for outer side terminal electrodes are led out from the outer side surface. This segmentation eliminates the need for sharp bends and complex crossing paths, making automatic winding machine handling easy while maintaining connection flexibility.
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
This configuration prevents wire lead sections from contacting incorrect terminal electrodes, enhancing connection reliability and facilitating wire lead-out and connection, thereby improving the handling and manufacturing efficiency of surface-mount pulse transformers.
Implementation Method 1
a drum core (2) having a winding core (3), a first flange (4A) provided at one end of the winding core (3) in a first direction (Y-direction), and a second flange (4B) provided at the other end of the winding core (3) in the first direction (Y-direction)
Data Source
AI summary
A pulse transformer is provided with a drum core 2 including a winding core 3 and first and second flanges 4A and 4B, and wires S1 to S4 wound around a winding core 3 of the drum core 2. Terminal electrodes 6a and 6b and a center tap 6c are provided on the flange 4A, and terminal electrodes 6d and 6e and a center tap 6f are provided on the flange 4B. Each end of the wires S1 to S4 is connected to a corresponding one of the terminal electrodes P1 and N1, the center tap CT2, the terminal electrodes P2 and N2, and the center tap CT1. A front end of the terminal electrode 6b is setback toward an outer side surface of the flange 4A, and a front end of the terminal electrode 6e is setback toward an outer side surface of the first flange 4B.