Transformer Bobbin Support Air Gap Insulation
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Solution Overview
Problem
The insulation performance of solid-state transformers deteriorates over time due to voids in insulating materials, leading to magnetic field concentration and increased costs.
Innovation Solution
A transformer design with a bobbin support part that maintains a uniform air gap between the magnetic core and the bobbin, preventing magnetic field concentration and ensuring stable insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating material is inserted between the core and the bobbin to maintain air gap, then insulation performance is improved, but the insulating material deteriorates over time generating voids which concentrate magnetic fields and reduce reliability
Solution Approach 1:
The invention extracts the problematic insulating material from the air gap between the core and bobbin, replacing it with a direct air gap structure. The bobbin support part provides the necessary spacing without requiring insulating material in the magnetic field path, eliminating the source of deterioration and void formation while maintaining insulation performance.
Solution Approach 2:
The bobbin support part acts as an intermediary element that maintains the air gap between the core and bobbin without requiring insulating material in the critical magnetic field region. This mediator provides both mechanical support and electrical insulation functions through the air gap structure, avoiding the reliability issues of deteriorating insulating materials.
2Volume of stationary object
If air gap between core and bobbin is reduced to make transformer smaller, then transformer size is reduced, but magnetic field concentration occurs causing insulation breakdown
Solution Approach 1:
The invention applies local quality by providing a uniform air gap specifically at the critical interface between the core and bobbin where magnetic field concentration occurs. The bobbin support part ensures consistent spacing in this high-stress region, maintaining insulation performance while allowing the rest of the transformer to be compact.
Solution Approach 2:
The invention changes the parameter of air gap uniformity by using the bobbin support part to maintain consistent spacing between the core and bobbin. This uniform air gap distribution prevents localized magnetic field concentration, allowing the transformer to be smaller without compromising insulation reliability.
3Reliability
If insulating material is used to maintain air gap, then insulation performance is improved, but transformer cost increases
Solution Approach 1:
The invention extracts the insulating material from the air gap structure, replacing it with a simpler air gap maintained by the bobbin support part. This elimination of insulating material reduces component count and assembly complexity, lowering manufacturing cost while maintaining insulation performance through the air gap structure.
Solution Approach 2:
The bobbin support part performs multiple functions: it maintains the air gap for insulation, provides mechanical support for the bobbin, and ensures uniform spacing. This multi-functionality eliminates the need for separate insulating materials, reducing cost and simplifying the overall structure.
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 provides reliable and stable insulation performance by maintaining a consistent air gap, reducing the risk of insulation breakdown and lowering costs by minimizing material degradation.
Implementation Method 1
the air gap between the core and the bobbin may become locally smaller. In this case, the problem is that a magnetic field concentration occurs in a portion between the core and the winding
Data Source
AI summary
In order to provide a transformer and an electric power converter which are less likely to become deteriorated with time and which have stable insulation performance, the transformer according to the present invention is provided with: a core; a bobbin in which a low-voltage-side primary winding and a high-voltage-side secondary winding are disposed along the central magnetic leg of the core; and a bobbin support part that supports the bobbin at an end of the bobbin on the primary winding side, such that an air gap is provided between the central magnetic leg of the core and a surface of the bobbin corresponding to the secondary winding.