Transformer Bobbin with Insulating Partition Collars for Loss Reduction
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Solution Overview
Problem
Conventional transformers face challenges in downsizing while maintaining high-frequency capabilities and reducing iron and copper losses, leading to increased size, heat generation, and insulation issues, particularly in vehicle-mounted chargers.
Innovation Solution
The transformer design incorporates a bobbin with a cylinder portion, insulating and winding partition collars, and split E-type cores to adjust leakage characteristics, enhance insulation, and facilitate α-winding, which reduces the number of winding layers, allows for larger wire diameters, and improves heat radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the number of turns of wire is increased to reduce iron losses, then magnetic flux density is decreased, but the size of the transformer becomes large and heat generation due to copper losses increases
Solution Approach 1:
The transformer windings are divided into multiple independent winding parts (first winding part, second winding part, third winding part) arranged axially on the cylinder portion. Each winding part is separated by insulating partition collars, allowing the windings to be segmented both spatially and functionally. This segmentation enables more efficient use of space and reduces the overall transformer volume while maintaining the required number of turns for low iron losses.
Solution Approach 2:
The patent transitions from conventional planar winding arrangements to a three-dimensional axial arrangement on a cylinder portion. The winding parts are positioned at different axial locations (first, second, third winding parts), utilizing the vertical dimension to pack more turns into a compact space. This dimensional change allows increased wire turns for reduced iron losses without proportionally increasing the transformer's footprint area.
2Power
If the wire diameter is increased to realize large current, then the coil winding part and ferrite core become large, but this causes insulation problems and increases iron losses
Solution Approach 1:
The windings are segmented into multiple parts with insulating partition collars between them. This segmentation allows each winding part to be optimized for its specific current requirements, enabling the use of appropriately sized wires without requiring the entire coil assembly to be oversized. The segmentation also improves insulation management by creating distinct insulated zones.
Solution Approach 2:
By arranging winding parts axially on the cylinder portion rather than in a conventional planar layout, the patent utilizes vertical space to accommodate larger diameter wires. The axial arrangement allows thick wires to be wound in separate layers at different heights, reducing the radial space required and preventing the coil winding part from becoming excessively large while maintaining high current capacity.
3Loss of energy
If the number of turns of wire is increased, then iron losses are reduced, but the height and plane size of the transformer increase
Solution Approach 1:
The windings are divided into multiple compact winding parts arranged axially, each with a moderate number of turns. The insulating partition collars separate these parts, allowing efficient space utilization. This segmentation enables the achievement of the required total number of turns for low iron losses while keeping the transformer height compact through optimized axial stacking of the winding parts.
Solution Approach 2:
The patent utilizes the axial dimension of the cylinder portion to arrange multiple winding parts vertically. By distributing turns across multiple axial positions rather than stacking them all in a single planar layer, the design achieves the necessary total turns for reduced iron losses while controlling the transformer's height and footprint through three-dimensional space optimization.
4Ease of manufacture
If conventional winding methods are used, then manufacturing is simple, but leakage characteristics cannot be adjusted and insulation is compromised
Solution Approach 1:
The insulating partition collars divide the winding structure into distinct insulated sections. Each winding part is manufactured and positioned as a separate unit, which simplifies the winding process for each individual part while the collars provide built-in insulation between parts. This segmentation approach maintains manufacturing simplicity through modular assembly while significantly improving insulation reliability between high-voltage and low-voltage windings.
5Ease of manufacture
If conventional winding methods are used, then manufacturing is simple, but leakage characteristics cannot be adjusted
Solution Approach 1:
The insulating partition collars create distinct, adjustable spacing between winding parts. The position and number of these collars can be modified to adjust the leakage inductance characteristics of the transformer. This segmented structure allows for versatile leakage characteristic adjustment while maintaining relatively simple manufacturing processes, as the collars can be positioned at different axial locations to achieve desired electrical characteristics.
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
This design achieves a compact, high-frequency capable transformer with improved insulation, reduced losses, and effective heat dissipation, enabling stable operation and cost-effective manufacturing.
Implementation Method 1
a magnetic core is inserted
Implementation Method 2
an insulating partition collar is formed
Data Source
AI summary
A transformer 10 comprises a bobbin 20. A cylinder portion 28 of the bobbin 20 is provided with a first winding part 35 where a first wire 37 is wound and a second winding part 36 where a second wire 38 is wound at a position different from the first winding part 35 in an axial direction. At an outer circumference of the cylinder portion 28 located between the first winding part 35 and the second winding part 36, an insulating partition collar 30 is formed. On the first winding part 35, a winding partition collar 33, separating in respective sections S1, S2, is formed. On the winding partition collar 33, at least one communication groove 33a, communicating the sections S1, S2 adjacent to each other is formed. The first wire 37 is α-wound around the first winding part 35.