Transformer Bobbin Design for Slim Display Noise Reduction
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Solution Overview
Problem
Conventional transformers used in thin display devices suffer from noise interference due to leakage magnetic flux and require manual production, limiting productivity and reliability.
Innovation Solution
A transformer design featuring inner and outer bobbins with through-holes and flange parts, allowing for automatic coupling and reduced magnetic flux leakage, along with a coil skip part for lead wire routing to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the back cover and transformer have a narrow interval to obtain slimness, then the thickness of the display device is reduced, but noise is generated due to interference between the back cover and leakage magnetic flux
Solution Approach 1:
A magnetic shielding member is introduced as an intermediary component between the transformer and the back cover. This shielding member intercepts and redirects the leakage magnetic flux, preventing it from reaching the back cover and causing noise. The shielding member acts as a mediator that resolves the conflict between maintaining narrow spacing for slimness and preventing magnetic interference that causes noise.
2Productivity
If manual production is used for the transformer, then assembly flexibility is maintained, but productivity is limited and reliability is reduced
Solution Approach 1:
The transformer is segmented into modular components including a bobbin, coil, core, and magnetic shielding member. These segmented components can be manufactured separately using automated processes and then assembled through standardized coupling mechanisms. The segmentation enables both automated high-volume production and consistent quality control, improving both productivity and reliability.
Solution Approach 2:
The transformer components are designed with nested structures where the core is inserted into the bobbin, and the magnetic shielding member is positioned between them. This nested arrangement creates a compact, pre-assembled unit that can be automatically manufactured and handled as a single module, enhancing both production efficiency and assembly reliability.
3Manufacturing precision
If a complex coupling structure is used for bobbins, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The coupling mechanism is merged into the basic structural design of the bobbin and core components. The bobbin includes integrated coupling features such as recesses and protrusions that directly engage with corresponding features on the core and magnetic shielding member. This merging of coupling functionality into the primary components achieves precise assembly without adding separate complex coupling mechanisms, thereby maintaining structural simplicity.
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 minimizes noise interference and enables automated production, enhancing the reliability and efficiency of thin display devices by securing insulation and preventing short circuits.
Implementation Method 1
a core electromagnetically coupled to the coils to thereby form a magnetic path
Implementation Method 2
a core electromagnetically coupled to the coils
Data Source
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AI summary
There are provided a thin transformer capable of being used in a thin display device such as a liquid crystal display (LCD) device, a light emitting diode (LED) device, and a flat panel display device including the thin transformer. The transformer includes a bobbin part including inner and outer bobbins each including a pipe shaped body part having a though-hole formed in an inner portion thereof and a flange part protruding outwardly from both ends of the body part; coils respectively wound around the inner and outer bobbins, and a core electromagnetically coupled to the coils to thereby form a magnetic path, wherein the outer bobbin includes a support part formed at the flange part formed at an upper end of the body part of the outer bobbin so as to cover a portion of the through-hole, and the inner bobbin is coupled to the outer bobbin while having one end supported by the support part.