Stacked Bobbin Transformer Layout for Lower Leakage Inductance
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Solution Overview
Problem
Conventional transformers with multi-winding designs have irregular winding arrangements around the magnetic core, leading to unstable product characteristics, high labor costs, and complex manufacturing processes, which hinder industrial automation and result in high power consumption and emissions.
Innovation Solution
The transformer design features two first windings disposed between the outer periphery of the bobbin main body and a second winding stacked sequentially, reducing leakage inductance and allowing for a simpler manufacturing process that facilitates automation, stability, and reduced volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-winding design with irregular arrangement around magnetic core is used, then transformer can perform multiple functions, but leakage inductance increases and product characteristics become unstable
Solution Approach 1:
The patent transitions from conventional radial arrangement around magnetic core to planar arrangement on circuit board. The windings are disposed in different layers (first winding in first layer, second winding in second layer) creating a three-dimensional stacked configuration that reduces leakage inductance while maintaining multi-functionality
Solution Approach 2:
The patent changes the spatial arrangement parameters of windings from irregular radial positions to precise planar positions on circuit board layers. The distance and relative positioning between windings are optimized to minimize leakage inductance while ensuring stable product characteristics
2Adaptability or versatility
If conventional irregular winding arrangement is used, then transformer can accommodate different functions, but manufacturing process becomes complex and cannot be automated
Solution Approach 1:
The patent uses circuit board layers as a structured platform to arrange windings in different levels. This planar multi-layer approach simplifies manufacturing by enabling automated PCB fabrication processes while maintaining the ability to accommodate multiple functions through different winding configurations on the same board
Solution Approach 2:
The circuit board serves as a universal platform that can accommodate different winding arrangements for various transformer functions. The same PCB structure can be used for different applications by simply changing the winding patterns and connections, reducing manufacturing complexity
3Adaptability or versatility
If conventional multi-winding design is used, then transformer can perform different functions, but labor cost increases and automation is hindered
Solution Approach 1:
By arranging windings on different layers of a circuit board, the patent enables automated PCB manufacturing processes to be used. This eliminates complex manual winding operations while maintaining multi-functionality through programmed circuit board designs
Solution Approach 2:
The patent replaces traditional mechanical winding processes with automated PCB fabrication and mounting processes. The windings are implemented as printed circuit traces or mounted components on the circuit board, allowing for high-volume automated production
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 reduces leakage inductance, enables easy automation, ensures stable product quality and dimensions, and achieves a more compact form while lowering power consumption and emissions.
Implementation Method 1
The two first windings are disposed around the winding portion. One of the two first windings is disposed between the other one of the two first windings and the outer periphery surface of the bobbin main body. The second winding is disposed around the winding portion and disposed between the two first windings.
Implementation Method 2
The magnetic core assembly includes a first magnetic core and a second magnetic core.
Data Source
AI summary
A transformer includes a magnetic core assembly, a bobbin, two first windings, a second winding and at least one circuit board. The bobbin includes a bobbin main body, a bobbin channel and a winding portion. The winding portion is formed on an outer periphery surface of the bobbin main body. The two first windings are disposed around the winding portion. One of the two first windings is disposed between the other one of the two first windings and the outer periphery surface of the bobbin main body. The second winding is disposed around the winding portion and disposed between the two first windings. The at least one circuit board includes a circuit board hole. The circuit board hole and the bobbin channel are communicated with each other. The magnetic core assembly partially penetrates through the circuit board hole and the bobbin channel.