Slim Transformer Coil Layout for Leakage Inductance and Heat Dissipation
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Solution Overview
Problem
Existing transformers used in flat panel display devices face challenges in achieving a slim design while maintaining sufficient leakage inductance and heat dissipation, with conventional slim-type transformers experiencing reduced leakage inductance and inefficient heat dissipation due to their structure.
Innovation Solution
A transformer design featuring a core unit with upper and lower cores, a coil unit, and a bobbin unit that includes first and second coils with specific spacing and overlapping configurations, along with insulating units and coil-fixing units, to enhance leakage inductance and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a general slim-type transformer is structured with primary coil and secondary coil stacked in the vertical direction, then the thickness of the transformer is reduced, but the leakage inductance decreases greatly
Solution Approach 1:
The patent transitions from vertical stacking to horizontal side-by-side arrangement of coils, utilizing the planar dimension instead of the vertical dimension to achieve both slimness and sufficient leakage inductance. The coils are arranged in the same horizontal plane with controlled spacing, converting the spatial relationship from vertical layering to horizontal positioning.
Solution Approach 2:
The patent applies different spacing distances to different regions: a first spacing distance in the first region and a second spacing distance in the second region. This local differentiation allows optimization of leakage inductance in specific areas while maintaining overall slimness, with the ratio of first to second spacing distance being 0.5 to 2.0.
2Length of stationary object
If a slim-type transformer is designed to reduce thickness, then the transformer becomes slimmer, but heat dissipation performance deteriorates
Solution Approach 1:
The patent arranges coils horizontally side-by-side rather than vertically stacking them, which expands the surface area exposed to air for heat dissipation while maintaining reduced thickness. This horizontal arrangement creates better thermal pathways without increasing the vertical dimension.
Solution Approach 2:
The patent divides the transformer into distinct regions with different spacing characteristics, creating separate thermal zones that can dissipate heat more effectively. The first and second regions with different spacing distances allow for optimized heat distribution and dissipation pathways.
3Reliability
If the spacing distance between primary coil and secondary coil is increased to improve leakage inductance, then leakage inductance increases, but the transformer thickness increases
Solution Approach 1:
The patent achieves increased leakage inductance by increasing horizontal spacing distance between coils rather than vertical spacing. The coils remain at the same vertical level, so the thickness is not increased, but the leakage inductance is improved through planar separation.
Solution Approach 2:
The patent implements different spacing distances in different regions (first spacing distance and second spacing distance) to locally optimize leakage inductance where needed while maintaining overall compactness. The ratio of first to second spacing distance being 0.5 to 2.0 allows flexible optimization.
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 design secures sufficient leakage inductance and improves heat dissipation by controlling the spacing between primary and secondary coils, allowing for a slimmer transformer with enhanced insulation and efficient energy conversion.
Implementation Method 1
a transformer according to an embodiment may include a core unit including an upper core and a lower core, a coil unit partially disposed in the core unit
Implementation Method 2
both the primary coil and the secondary coil stacked in the vertical direction have an influence on the thickness of the transformer. Therefore, there is a limitation with regard to reduction in the thickness of the transformer, and leakage inductance decreases greatly
Data Source
AI summary
A transformer according to one embodiment of the present invention comprises: a core unit including an upper core and a lower core; a coil unit of which a portion is disposed in the core unit; and a bobbin unit disposed between the core unit and the coil unit, wherein the coil unit includes a first coil and a second coil of which at least a portion is disposed on the side surface of the first coil, the core unit includes a first outer foot part, a second outer foot part, and an intermediate foot part disposed between the first outer foot part and the second outer foot part, and the shortest distance between the first coil and the second coil can be 0.1 to 0.3 times the shortest distance between the outermost part of the first coil and an adjacent outer foot part from among the first outer foot part and the second outer foot part.