Transformer Height Maintenance via Bent Pin Support
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Solution Overview
Problem
Conventional transformers face challenges in reducing their height without increasing the size of the circuit board and lack adjustable mechanisms for maintaining height in compact electronic devices.
Innovation Solution
A transformer design featuring a winding module with a winding pillar and baseboard, supported by magnetic core modules and pins with a supporting means, such as a heel block or bushing, to maintain height and reduce overall height by utilizing a smaller receiving hole on the circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the transformer height is reduced to fit compact electronic devices, then the space efficiency is improved, but the winding module cannot be properly formed and the circuit board hole must be enlarged
Solution Approach 1:
The transformer is divided into separate magnetic core modules (first and second magnetic core modules) that can be assembled around the winding module. This segmentation allows the winding module to be formed first in a compact space, then the magnetic core modules are attached to complete the transformer without requiring a large pre-formed hole in the circuit board.
Solution Approach 2:
The winding module is nested within the magnetic core modules, with the winding pillar extending through the magnetic core modules. This nested arrangement allows the entire transformer assembly to fit through a small receiving hole in the circuit board while maintaining proper transformer geometry and function.
2Volume of moving object
If the transformer height is dramatically reduced, then the space efficiency is improved, but the height cannot be maintained and adjusted
Solution Approach 1:
The pin is designed with a bent portion that can be elastically deformed during assembly. By applying force to the pin, the bent portion flexes to allow the magnetic core modules to be positioned at different heights relative to the circuit board, then the pin maintains the selected height position. This provides adjustable height functionality in a compact design.
Solution Approach 2:
The height of the transformer can be adjusted by changing the degree of bending of the pin's bent portion. By varying the bend angle or position, different height configurations are achieved, allowing the transformer to be adapted to different space requirements while maintaining a compact overall size.
3Volume of moving object
If the winding module height is reduced by forming bent parts on pins, then the height is reduced, but the total height including magnetic core cannot be dramatically decreased and the circuit board area is increased
Solution Approach 1:
Instead of reducing height only in the vertical dimension by bending pins, the solution utilizes the horizontal arrangement of magnetic core modules around the winding pillar. The magnetic core modules are positioned laterally around the winding structure, allowing compact vertical profile while maintaining proper magnetic path geometry without requiring excessive circuit board area.
Data Source
AI summary
A transformer capable of maintaining its height is provided. The transformer is formed on a circuit board having a receiving hole. The transformer comprises a winding module, two magnetic core modules contacting and holding the winding module, a plurality of pins and at least one supporting means. The winding module comprises a winding baseboard and a winding pillar where a winding structure is formed thereon. The winding pillar is received in the receiving hole. Each of the pins comprises a first bent part separating the corresponding pin into a first portion connected to the winding baseboard and a second portion connected to the circuit board around the receiving hole. The supporting means is formed between the first portion of at least one of the pins and the circuit board to contact the first portion and the circuit board to maintain the distance between them.