Thin Transformer Bobbin Design for Automated Assembly
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Solution Overview
Problem
The production of transformers for thin display devices is limited by manual processes, leading to low productivity and quality issues, particularly in securing insulation distances between primary and secondary coils.
Innovation Solution
A transformer design featuring a bobbin part with inner and outer bobbins, where the inner bobbin is inserted into the outer bobbin to form a magnetic path, with flange parts and insulating ribs to secure insulation and prevent bending, allowing for automated production and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual production process is used for transformer assembly, then flexibility in handling complex insulation requirements is improved, but productivity is reduced and quality consistency deteriorates
Solution Approach 1:
The transformer is divided into modular components (primary coil assembly, secondary coil assembly, bobbin, yoke) that can be independently manufactured and then automatically assembled. This segmentation allows each component to be optimized for automated production while maintaining the complexity needed for proper insulation and electrical isolation.
Solution Approach 2:
The bobbin serves as an intermediary component that provides structural support and electrical insulation between the primary and secondary coils. The flange parts of the bobbin create physical separation and insulation barriers, enabling automated assembly while maintaining reliable electrical isolation without manual intervention.
2Reliability
If insulation distance between primary and secondary coils is increased, then electrical insulation reliability is improved, but device size increases
Solution Approach 1:
Instead of increasing insulation distance in a single direction, the design utilizes three-dimensional spatial arrangement with the bobbin structure providing insulation in multiple directions. The flange parts extend in different directions to create insulation barriers, achieving reliable electrical isolation within a compact footprint by exploiting dimensional space efficiently.
Solution Approach 2:
The primary and secondary coils are nested around the same bobbin structure, with the bobbin and its flange parts providing insulation between them. This nested arrangement allows for compact sizing while maintaining adequate insulation distances through the radial and axial positioning of coils relative to the bobbin's insulating surfaces.
3Strength
If flange parts are made wider to prevent bending, then structural strength is improved, but device thickness increases
Solution Approach 1:
The bobbin is constructed from insulating material with high mechanical strength properties, allowing the flange parts to achieve adequate anti-bending strength without excessive width. The material composition provides both the necessary structural rigidity and electrical insulation properties, enabling compact dimensions while maintaining strength.
Solution Approach 2:
The flange parts are designed with curved surfaces rather than flat surfaces, providing increased structural strength and resistance to bending forces. The curved geometry distributes stress more effectively, allowing for thinner flange parts that maintain adequate strength while reducing overall transformer thickness.
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 enables efficient, automated production of thin transformers with secure insulation distances between coils, enhancing productivity and quality while minimizing size and protrusion, suitable for use in thin display devices.
Implementation Method 1
a core inserted into the through-hole of the bobbin to thereby form a magnetic path
Implementation Method 2
a coil part including coils each wound around the plurality of bobbins
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 external connection terminals protruding from one side of a lower flange part formed at a lower end of the body part; 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 inner bobbin and an outer bobbin, and the inner bobbin is coupled to the outer bobbin such that the external connection terminals of the inner bobbin and the external connection terminals of the outer bobbin are opposed to each other.