SMT Network Transformer Module With Integrated TVS and Filters
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Solution Overview
Problem
Conventional network transformer manufacturing is labor-intensive, time-consuming, and cannot be automated using Surface Mount Technology (SMT), leading to inefficiencies, high error rates, and increased costs, while also limiting miniaturization due to the need for larger circuit boards and manual assembly processes.
Innovation Solution
An inductor-type network transformer design that incorporates a chip-type transformer, common-mode filter, and peripheral elements like capacitors, resistors, and TVS diodes on a circuit board, all covered by a casing, utilizing SMT for assembly and integration of these components within the casing to avoid manual processes and enhance robustness and miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual assembly process is used for conventional network transformers, then components can be assembled, but the manufacturing process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent combines the transformer member, peripheral elements (capacitors, resistors, TVS diodes), and casing into a single integrated module that can be mounted as one unit onto the circuit board. This merging eliminates the need for separate manual assembly steps for each component, enabling automated SMT production while maintaining complete functionality.
Solution Approach 2:
The transformer member and peripheral elements are pre-assembled into a complete module before being mounted onto the circuit board. The casing is also prepared in advance as a complete enclosure. This preliminary assembly allows the final installation to be a single automated step, dramatically improving manufacturing efficiency.
2Ease of operation
If peripheral elements are disposed outside the casing, then they can be accessed, but the circuit board dimension must be greater than the casing, limiting miniaturization
Solution Approach 1:
All peripheral elements (capacitors, resistors, TVS diodes) are integrated inside the casing along with the transformer member, eliminating the need for external component placement. This integration allows the circuit board footprint to match the casing dimensions exactly, enabling miniaturization while maintaining all necessary functionality.
3Ease of manufacture
If manual welding process is used for transformer member, then components can be connected, but the process cannot be automated using SMT
Solution Approach 1:
The transformer member with its lead wires is pre-assembled into a complete module with all peripheral elements and the casing. This integrated module has standardized mounting features that are compatible with automated SMT pick-and-place machines, eliminating the need for manual welding while maintaining reliable electrical connections.
4Ease of manufacture
If conventional manual assembly is used, then components can be installed, but the process has high error rate and high cost
Solution Approach 1:
By integrating all components into a single pre-assembled module, the number of separate assembly steps is reduced to one automated mounting operation. This eliminates multiple opportunities for human error in manual assembly, welding, and component placement, dramatically improving manufacturing accuracy and reducing costs through automation.
Data Source
AI summary
The inductor-type network transformer includes a circuit board, at least one transformer member mounted to the circuit board, at least one peripheral element mounted to the circuit board to a side of the transformer member, and a casing configured on the circuit board completely covering the at least one transformer member, and the at least one peripheral element. The present invention configures at least a transformer member and at least a peripheral element on a circuit board through Surface Mount Technology (SMT), which are all entirely covered by a casing, thereby avoiding the conventional manual process's complexity and inconvenience, and enhancing production cost and efficiency. As the peripheral elements, such as Transient Voltage Suppressor (TVS) diodes, are also integrated inside the casing, the network transformer is more robust to electrical shocks. The integration of the peripheral elements inside the casing also helps to product miniaturization.