Slim Transformer Bobbin with Partition Plates and Embedded Core
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Solution Overview
Problem
Conventional transformers face challenges in precisely controlling leakage inductance, maintaining electrical safety, and conforming to slim designs due to complex assembly processes and increased height, which affects the integrity and strength of pins and electrical connections.
Innovation Solution
A slim-type transformer design featuring multiple bobbins with partition plates and a magnetic core assembly, where the primary and secondary winding coils are separated by partition plates, and the magnetic core legs are embedded into channels with spacers to adjust leakage inductance and maintain electrical safety, while L-shaped pins ensure structural integrity and reduced height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional transformer uses upper and lower covering members to increase creepage distance, then electrical safety is improved, but the height of the transformer increases and the assembly process becomes complicated
Solution Approach 1:
The patent merges the functions of the upper and lower covering members into the bobbin structure itself. The bobbin is designed with integrated insulating features and structural elements that previously required separate covering members, thereby simplifying the assembly process while maintaining electrical safety and creepage distance requirements.
Solution Approach 2:
The bobbin is designed to perform multiple functions: it serves as the structural support for winding coils, provides the necessary creepage distance for electrical safety, and replaces the need for separate upper and lower covering members. This multi-functional design reduces the total number of components and simplifies assembly.
2Reliability
If the conventional transformer uses upper and lower covering members to increase creepage distance, then electrical safety is improved, but the height of the transformer increases
Solution Approach 1:
The patent combines the functions of separate covering members into the integrated bobbin structure, eliminating the need for additional height-consuming components while maintaining the required creepage distance for electrical safety through the bobbin's own structural design.
Solution Approach 2:
The patent optimizes the creepage distance by utilizing the radial and axial dimensions of the bobbin structure rather than adding height through separate covering members. The insulating design and winding arrangement within the bobbin provide adequate creepage paths without increasing the overall transformer height.
3Ease of manufacture
If the output terminals are directly wound and welded on pins, then the assembly is simplified, but the integrity of pins is compromised and structure strength is deteriorated
Solution Approach 1:
The patent segments the pin structure into distinct functional portions: an embedded portion within the bobbin that provides structural support and anchoring, and an external terminal portion for electrical connections. This segmentation allows the pin to maintain its structural integrity while facilitating winding and welding operations on the terminal portion without compromising the embedded portion.
4Device complexity
If the magnetic core assembly is combined with the bobbin, then the structure is compact, but the leakage inductance cannot be precisely controlled
Solution Approach 1:
The patent incorporates adjustable or selectable spacer elements between the magnetic core assembly and the bobbin, allowing the distance to be varied. This dynamic adjustment capability enables precise control of leakage inductance while maintaining a compact overall structure, as the spacers provide a simple mechanism for tuning the magnetic coupling without requiring complex external adjustments.
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 effectively controls leakage inductance, enhances electrical safety, and reduces the overall height of the transformer, maintaining the integrity of pins and electrical connections, thus improving the transformer's performance and safety.
Implementation Method 1
the magnetic core assembly partially embedded into the channels of the bobbins and sustained against the spacer
Implementation Method 2
A transformer has become an essential electronic component for voltage regulation into required voltages for various kinds of electric appliances
Data Source
AI summary
A transformer includes multiple bobbins arranged side by side, a primary winding coil, a secondary winding coil and a magnetic core assembly. Each bobbin includes a main body, multiple partition plates, a primary winding coil, a secondary winding coil and a magnetic core assembly. The main body has at least two sidewalls respectively disposed at two opposite ends thereof. The partition plates are disposed on the main body for respectively cooperating with the sidewalls to define a first winding region and a second winding region. The first winding region and the second winding region are separated by the partitions plates. The spacer is disposed within the channel. The primary winding coil and the secondary winding coil are respectively wound on the first winding portion and the second winding portion of each bobbin. The magnetic core assembly partially embedded into the channels of the bobbins and sustained against the spacer.