Transformer Bobbin Design for 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 coupled inner and outer bobbins with specific flange and protrusion configurations allows for automatic production and reduced magnetic flux leakage, enabling efficient coupling and insulation for noise reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If coils are wound perpendicularly to the printed circuit board with a core forming a magnetic path in parallel, then the transformer can be mounted on the board, but leakage magnetic flux causes noise interference when the back cover and transformer have a narrow interval

Engineering Contradiction:

Improvemounting convenienceVSAvoidnoise interference from leakage magnetic flux

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the conventional winding direction by winding coils in parallel to the printed circuit board instead of perpendicularly. This reversal changes the magnetic flux distribution pattern, directing leakage flux away from the back cover space and eliminating noise interference while maintaining mounting convenience

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the orientation parameter of coil winding from perpendicular to parallel relative to the printed circuit board. This parameter change fundamentally alters the magnetic field geometry, reducing leakage flux in the critical space between the back cover and transformer

Inventive Principle:

Principle #35Parameter changes

2Productivity

If manual production processes are used for transformer assembly, then flexibility is maintained, but productivity is limited and reliability is reduced

Engineering Contradiction:

Improveproduction efficiencyVSAvoidproduction reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent segments the transformer into modular components (bobbin, coil, core) with standardized interfaces. The bobbin includes positioning protrusions and insertion holes that enable precise automated assembly. This segmentation allows each component to be manufactured and assembled separately through automated processes, improving both productivity and reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces manual mechanical assembly with automated insertion mechanisms. The bobbin design with positioning protrusions and insertion holes enables automated robots to accurately position and assemble components, eliminating manual labor while enhancing consistency and reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Length of moving object

If the back cover and transformer have a narrow interval to achieve slim display devices, then device thickness is reduced, but leakage magnetic flux causes back cover vibration and noise

Engineering Contradiction:

Improvedevice thicknessVSAvoidback cover vibration and noise

Core Design Contradiction:

Length of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the conventional coil winding orientation to parallel with the printed circuit board. This inversion redirects the magnetic flux paths, causing leakage flux to travel parallel to the back cover rather than perpendicular to it, thereby eliminating the vibration and noise issues even when the interval is narrow

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the spatial orientation parameter of the magnetic field by winding coils parallel to the board instead of perpendicularly. This parameter change fundamentally alters the leakage flux distribution, allowing narrow intervals without causing back cover vibration

Inventive Principle:

Principle #35Parameter changes

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 transformer design enhances productivity through automated manufacturing, reduces noise interference by minimizing leakage magnetic flux, and ensures reliable operation in thin display devices.

Implementation Method 1

a core electromagnetically coupled to the coils to thereby form a magnetic path

Methodology Applied

Scientific EffectElectromagnetic coupling: Electromagnetic Induction

Data Source

PatentUS8742878B2Transformer and flat panel display device including the same

Publication Date: 2014.06.03 SOLUM CO LTD

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) display device, and a flat panel display device including the same. 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 inner bobbin is inserted into the through-hole of the outer bobbin to thereby be coupled to the outer bobbin and at least one of the inner and outer bobbins includes the flange part having a width larger than a thickness of the body part.