Shielded Mold Transformer for Electric Field Relaxation
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Solution Overview
Problem
Mold transformers face issues with concentrated electric field distribution on the surface of insulating materials, leading to reduced insulation performance and potential component damage.
Innovation Solution
The mold transformer design includes a winding part, a shield member made of electrically conductive material, and a mold part made of electrical insulation material. The shield member is shaped to concentrate part of the electric field inside the mold part, thereby relaxing the electric field distribution around the transformer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid insulator is used to wrap the high-voltage winding part, then insulation performance is improved, but electric field concentration occurs on the surface of the insulating material
Solution Approach 1:
A shield member made of conductive material is introduced as an intermediary between the high-voltage winding and the insulating material. This shield member redistributes the electric field lines, preventing concentration at the insulator surface while maintaining insulation effectiveness.
Solution Approach 2:
The electric field distribution is modified by changing the physical parameters of the system - specifically by introducing a conductive shield that alters the electric field density and direction, transforming the harmful concentrated field into a more uniform distribution.
2Reliability
If the thickness of epoxy resin is increased to improve insulation, then manufacturing complexity and cost increase
Solution Approach 1:
Instead of increasing the thickness parameter of the insulating material, the solution changes the electric field distribution parameters through the shield member, achieving the same insulation effect with optimized rather than increased dimensions.
Solution Approach 2:
The system uses a composite structure combining conductive shield material with insulating material, creating a multi-functional assembly that provides both field control and insulation without requiring excessive thickness of any single material.
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 design improves the insulation performance of the mold transformer by reducing leakage current and enhancing voltage transformation reliability, while also simplifying the manufacturing process.
Implementation Method 1
The shield member is shaped to concentrate part of the electric field inside the mold part, thereby relaxing the electric field distribution around the transformer
Implementation Method 2
Transformers are devices that change current or voltage by using electromagnetic induction
Data Source
AI summary
The present disclosure discloses a mold transformer which is capable of further relaxing the ambient electric field distribution thereof, the mold transformer comprising: a winding part; a shield member formed in a columnar shape having a hollow space formed therein and formed of an electrically conductive material, wherein a part of a lead wire of the winding part is inserted through and coupled to the hollow space; and a mold part disposed to surround the winding part and the shield member and formed of an electrical insulation material.