Thin Transformer Bobbin Design for Automated Assembly
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Solution Overview
Problem
The production of transformers for thin display devices is hindered by manual processes, leading to limitations in productivity and quality, and there is a need for a transformer that can be easily mounted on a substrate and automatically produced.
Innovation Solution
A transformer design featuring a bobbin part with a pipe-shaped body, flange parts, and terminal connection parts, along with a core and coil configuration that allows for easy assembly and insulation, enabling automated production and integration into thin display devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual production process is used for transformer, then flexibility in handling complex assembly is maintained, but productivity is limited and quality consistency cannot be ensured
Solution Approach 1:
The transformer is divided into separate modular components: bobbin part, core, and coil part. Each component can be manufactured independently using automated processes, then assembled together. This segmentation enables automated production while maintaining the complexity of the overall device through standardized interfaces between modules.
Solution Approach 2:
The bobbin part is pre-assembled with the core inserted into the through-hole before coil winding. This preliminary assembly creates a stable base structure that simplifies subsequent automated coil winding and terminal connection processes, enabling full automation while handling assembly complexity.
2Length of stationary object
If transformer thickness is reduced for thin display devices, then integration into thin displays is improved, but manufacturing precision requirements increase
Solution Approach 1:
The core is inserted into the through-hole of the bobbin part, creating a nested structure where the core is contained within the bobbin. This nesting arrangement minimizes the overall thickness of the transformer while maintaining proper spacing and alignment through the structural relationship between the nested components, reducing thickness without requiring extreme manufacturing precision.
Solution Approach 2:
The terminal connection part protrudes in the outer diameter direction rather than extending the thickness dimension. This dimensional change allows electrical connections to be made without increasing transformer thickness, enabling thin profile while maintaining connection functionality through a different spatial dimension.
3Ease of operation
If terminal connection part protrudes in outer diameter direction, then ease of mounting on substrate is improved, but device complexity increases
Solution Approach 1:
The terminal connection part serves multiple functions: it provides electrical connection terminals, acts as a mounting interface for securing the transformer to the substrate, and maintains structural integrity of the bobbin assembly. This multi-functionality reduces the need for separate mounting components, simplifying the overall device structure despite the protruding terminal design.
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 solution enables the production of thin, high-quality transformers that can be easily integrated into thin display devices, improving productivity and ensuring reliable electrical connections while minimizing size and enhancing insulation properties.
Implementation Method 1
a core inserted into the through-hole of the bobbin to thereby form a magnetic path
Data Source
AI summary
There is provided a thin transformer capable of being used in a thin display device such as a liquid crystal display (LCD) device and a light emitting diode (LED) display device. The transformer includes: a bobbin part including a plurality of bobbins, each including a pipe shaped body part having a though-hole formed in an inner portion thereof, a flange part vertically protruding outwardly from both ends of the body part, and a terminal connection part protruding from one side of a lower flange part formed at a lower end of the body part and having external connection terminals connected thereto; a core inserted into the through-hole of the bobbin to thereby form a magnetic path; and a coil part including coils each wound around the plurality of bobbins, wherein the bobbin part includes an outer bobbin and an inner bobbin inserted into the through-hole of the outer bobbin to thereby be coupled thereto, and the terminal connection part of the inner bobbin protrudes in an outer diameter direction thereof.