Transformer Base Insertion for Creepage Distance and Miniaturization
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Solution Overview
Problem
Conventional transformers face challenges in miniaturization and manufacturing complexity due to space constraints and safety standards, particularly in ensuring a sufficient creepage distance between the coil and magnetic core, which complicates assembly and increases production costs.
Innovation Solution
A transformer design featuring a magnetic core with a coil unit and a base that uses an insertion coupling structure to secure the creepage distance between the magnetic core and output terminal, allowing for miniaturization while simplifying assembly and reducing manufacturing costs through a laminated coil structure and PCB integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the creepage distance between the coil and magnetic core is increased to meet safety standards, then the insulation performance is improved, but the transformer size increases and miniaturization is hindered
Solution Approach 1:
The base is inserted into the coil unit along the thickness direction (vertical dimension) rather than increasing the planar dimensions. This allows the creepage distance to be achieved in the vertical dimension, maintaining compact planar footprint while meeting insulation requirements.
Solution Approach 2:
The base is nested within the coil unit structure, with the base inserted into the coil unit along the thickness direction. This nested arrangement allows the base to provide the necessary creepage distance without adding external volume to the transformer.
2Ease of manufacture
If the conventional winding structure is used, then the transformer can be manufactured with traditional methods, but the manufacturing process is complicated and assembly efficiency is reduced
Solution Approach 1:
The transformer is divided into distinct modules: the coil unit with integrated PCB and windings, and the separate base component. This segmentation allows each module to be manufactured and prepared independently, then quickly assembled together, improving overall assembly efficiency.
Solution Approach 2:
The coil unit is prepared in advance with the PCB and windings integrated before assembly with the base. The base is also prepared separately with the insertion portion formed beforehand. This preliminary preparation of components enables faster final assembly and improves productivity.
3Reliability
If the creepage distance is secured through conventional spacing, then the safety requirements are met, but the manufacturing complexity increases due to space constraints
Solution Approach 1:
The base and coil unit are merged into an integrated assembly where the base is inserted into the coil unit. This merging eliminates the need for separate spacing components and complex assembly procedures, reducing manufacturing complexity while maintaining the required creepage distance.
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 achieves miniaturization, improved assembly efficiency, and cost reduction by ensuring adequate insulation and creepage distance, enhancing the overall manufacturing process and product performance.
Implementation Method 1
A portion of the base is inserted into and disposed in the coil unit to be interposed between an output terminal coupled to the secondary coil and the magnetic core
Implementation Method 2
The transformer may generate an induced electromotive force in the secondary coil through power applied to the primary coil
Data Source
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AI summary
A transformer includes a magnetic core having an inner space, a coil unit disposed within the magnetic core and including a primary coil and a secondary coil in which layers formed with conductive patterns are laminated, and a base configured to receive the magnetic core and the coil unit. A portion of the base is inserted into and disposed in the coil unit to be interposed between an output terminal coupled to the secondary coil and the magnetic core.