Slim Transformer Bobbin With Insulation Protrusion
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Solution Overview
Problem
Conventional transformers face challenges in miniaturization and slimness due to increased volume and fabricating costs from insulation cases, which restrict their application on circuit boards.
Innovation Solution
A slim-type transformer design featuring a bobbin with a supporting part and a bracket that assists in positioning the secondary winding coil's fly lines, reducing overall volume and using an insulation medium instead of an insulation case for cost-effectiveness and enhanced space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation case is used to isolate the primary winding coil and secondary winding coil, then electrical safety is improved, but the overall volume and fabricating cost increase
Solution Approach 1:
The patent integrates the insulation function directly into the bobbin structure by adding an insulation protrusion that extends from the bobbin's sidewall. This combines the bobbin's structural support function with the insulation function, eliminating the need for a separate insulation case and thereby reducing overall volume while maintaining electrical safety between primary and secondary windings.
Solution Approach 2:
The bobbin is designed with multi-functionality: it provides structural support for winding coils, positions the fly line of the secondary winding coil through its protrusion, and simultaneously provides electrical insulation between primary and secondary windings. This multi-functional design eliminates the need for separate insulation components, reducing volume and component count.
2Reliability
If an insulation case is used to isolate the primary winding coil and secondary winding coil, then electrical safety is improved, but the fabricating cost increases
Solution Approach 1:
The insulation function is merged into the bobbin structure through the insulation protrusion, eliminating the need for a separate insulation case. This reduces the number of components that need to be manufactured and assembled, thereby reducing fabricating cost while maintaining electrical safety.
Solution Approach 2:
The bobbin serves multiple functions including structural support, coil positioning, and electrical insulation. By making the bobbin multi-functional, the patent eliminates the need for separate insulation components, reducing component count and assembly steps, which directly reduces fabricating cost.
3Manufacturing precision
If a base with positioning structure is extended from the bobbin to position the fly line, then positioning accuracy is improved, but the length and height increase
Solution Approach 1:
Instead of extending the positioning structure along the length or height of the bobbin, the patent utilizes the radial dimension by forming an insulation protrusion from the bobbin's sidewall. This positioning protrusion extends radially outward to engage with the fly line, achieving accurate positioning without increasing the overall length or height of the transformer.
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 achieves reduced volume and cost-effective assembly while ensuring electrical safety and easy positioning of the secondary winding coil, meeting the requirements of miniaturization and slimness.
Implementation Method 1
the magnetic core assembly is subject to electromagnetic induction, and a regulated voltage is outputted from the secondary winding coil
Data Source
AI summary
A transformer includes a bobbin, a winding coil assembly, a magnetic core assembly, and a bracket. The bobbin includes a supporting part and a winding part. The winding coil assembly includes a primary winding coil and a secondary winding coil. The secondary winding coil has an outlet part. The primary winding coil and the secondary winding coil are wound around the winding part of the bobbin. The magnetic core assembly includes a first magnetic core and a second magnetic core. The bobbin is arranged between the first magnetic core and the second magnetic core. The bracket is connected with the supporting part of the bobbin for assisting in positioning the outlet part of the secondary winding coil.