Reverse-Structure Transformer for More Coil Turns in Low Height
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Solution Overview
Problem
Transformers with a normal structure face limitations in increasing coil turns while meeting height standards, leading to increased size, cost, and defect rates due to safety and manufacturing issues.
Innovation Solution
A transformer with a reverse structure featuring an inner and outer bobbin configuration, including insulating caps and specific terminal arrangements, allows for increased coil turns and creepage distance, reducing size and cost while ensuring safety compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the body part height is reduced to meet the defined height standard, then the transformer height is reduced, but the coil turns are decreased
Solution Approach 1:
The external connection terminal is inverted from the conventional lower flange position to the upper flange position. This inversion allows the coil to be wound more efficiently within the body part, increasing the number of turns that can be accommodated within the same height constraint, thereby resolving the contradiction between reduced height and sufficient coil turns.
2Reliability
If the spacing distance between primary terminal and secondary winding coil is increased to meet safety standards, then the safety distance is secured, but the bobbin size and unit cost are increased
Solution Approach 1:
The safety distance requirement is satisfied by utilizing the vertical dimension through the insulating cap structure rather than increasing the horizontal spacing. The insulating cap extends vertically from the upper flange to provide the required creepage distance, allowing tighter horizontal packing and smaller bobbin dimensions while still meeting safety standards.
3Reliability
If the bobbin size is increased to accommodate safety spacing, then the safety distance is secured, but the defect rate due to damage in manufacturing and transporting is increased
Solution Approach 1:
By inverting the terminal position to the upper flange and using the insulating cap to provide vertical creepage distance, the overall transformer dimensions are reduced. This compact design is more resistant to damage during manufacturing and transportation, thereby reducing the defect rate while still maintaining the required safety distances.
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 reverse structure enhances coil turn capacity, decreases transformer thickness, and lowers defect rates by maintaining safety standards and improving manufacturing efficiency.
Implementation Method 1
a core electrically coupled to the coils to form a magnetic circuit
Data Source
AI summary
A transformer having a reverse structure includes: a bobbin part including an inner bobbin and an outer bobbin including, respectively, body parts having through-holes formed therein and having a tubular shape and flange portions protruding outwardly from both ends of the body parts; coils respectively wound in the inner bobbin and the outer bobbin; and a core electrically coupled to the coils to form a magnetic circuit, wherein the inner bobbin and the outer bobbin include, respectively, external connection terminals fastened to one ends of the flange portions formed at an upper end of the body part and bent in a downward direction.