Shielded Transformer Core Assembly for Stable Inductance
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Solution Overview
Problem
Conventional transformers experience reduced stability and performance due to air gaps between cores, leading to positional displacement and conduction failures, which affect inductance and board mounting efficiency.
Innovation Solution
A transformer design incorporating a shield case with sandwiching members on its inner walls to securely position and align cores, eliminating air gaps and ensuring strong contact between cores, thereby stabilizing inductance and preventing positional displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If cores are brought into strong contact to prevent positional displacement, then stability of inductance is improved, but device complexity increases due to additional fixing mechanisms
Solution Approach 1:
The shield case is integrated with sandwiching members that directly contact and position the cores, merging the shielding function with the core positioning function into a single structural component, thereby eliminating the need for separate fixing mechanisms
Solution Approach 2:
The sandwiching members on the inner wall of the shield case automatically position and constrain the cores through their geometric configuration, allowing the structure to self-align and secure the cores without external fixing devices
2Reliability
If shield case is used to surround cores, then protection and alignment are improved, but manufacturing complexity increases
Solution Approach 1:
The shield case serves multiple functions simultaneously: it provides electromagnetic shielding, mechanically protects the cores, and through integrated sandwiching members, positions and aligns the cores, thereby reducing the need for additional specialized components
Solution Approach 2:
The inner wall of the shield case is segmented with discrete sandwiching members at specific locations, allowing targeted positioning of cores without requiring a completely complex integrated structure, simplifying manufacturing while maintaining functionality
3Stability of the object's composition
If air gap between cores is reduced, then inductance stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sandwiching members act as intermediary elements between the shield case and the cores, providing a mechanical interface that maintains precise spacing and alignment, thereby achieving consistent air gaps without requiring extremely high manufacturing precision in the core components themselves
Solution Approach 2:
The design changes the positioning parameter from direct core-to-core contact or tight tolerances to a system where sandwiching members define the spacing, allowing for more relaxed manufacturing tolerances while maintaining consistent air gap dimensions
Data Source
AI summary
A transformer in which a core portion has a hollow portion extending in a front-back direction, a conductive wire is wound around the core portion, a first core and a second core are formed by a material including a magnetic substance, and a shield case is formed by a material that has conductive properties, the shield case having a box shape surrounding the first core and the second core from a front-back direction, an up direction, and a left-right direction of the transformer, front convex portions and back convex portions being provided on an inner wall surface of the shield case and sandwiching the first core and the second core along the front-back direction, and left convex portions and right convex portions being provided on the inner wall surface of the shield case and sandwiching the first core and the second core along the left-right direction.