Transformer Bobbin Partitioning Flanges for Saturation Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High voltage transformers face saturation issues due to increased magnetic flux density, leading to harmonic frequency generation, reduced durability, and vibration, which necessitate larger sizes and higher manufacturing costs to prevent saturation and maintain insulation between coils.
Innovation Solution
The transformer design incorporates a bobbin with partitioning flanges to divide the winding surface, allowing the second coil to be wound on both sides of the bobbin, eliminating the need for layer insulation and enabling more turns without increasing the transformer's volume, thus maintaining proper insulation and reducing the risk of surface discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the turns of the first coil are increased to prevent saturation, then the magnetizing inductance increases and saturation is prevented, but the turns of the second coil must also be increased proportionally, requiring larger core size and increasing transformer volume
Solution Approach 1:
The patent transitions from single-layer winding to multi-layer winding configuration, utilizing the vertical dimension (layer stacking) to increase the number of turns without proportionally increasing the core length. This allows achieving the required magnetizing inductance while controlling the overall transformer volume.
Solution Approach 2:
The patent implements nested winding structures where multiple layers of coils are wound around each other or stacked vertically. The first and second coils are arranged in multiple layers, with insulating layers and support structures nested between them, maximizing space utilization and reducing overall volume.
2Reliability
If the turns of the first and second coils are increased to prevent saturation, then the magnetizing inductance increases, but the manufacturing cost increases due to larger core size and more materials
Solution Approach 1:
The nested winding structure allows efficient use of core material and coil wire by stacking layers vertically rather than extending horizontally. This reduces the amount of magnetic core material and insulation material required, thereby lowering manufacturing costs while maintaining the necessary number of turns.
Solution Approach 2:
By utilizing the vertical layering dimension, the design achieves the required number of turns without proportionally increasing material consumption. The multi-layer configuration optimizes material usage efficiency, reducing overall manufacturing costs.
3Quantity of substance
If the winding area is increased by increasing the core length, then more turns can be accommodated, but the volume of the transformer increases
Solution Approach 1:
Instead of increasing the horizontal winding area by extending core length, the patent utilizes the vertical dimension by stacking multiple layers of coils. This allows accommodating more turns while maintaining a compact core size and controlling the overall transformer volume.
Solution Approach 2:
The winding structure is segmented into multiple layers, with each layer containing a portion of the total turns. The support structures and insulating layers are also segmented and positioned at specific intervals, allowing efficient space utilization and reducing the required core length.
4Quantity of substance
If multiple layers of the second coil are wound on the bobbin, then the required turns can be achieved, but layer insulation becomes necessary and the winding region continuously decreases
Solution Approach 1:
The second coil is segmented into multiple layers, with insulating layers positioned between them. The support structures are strategically placed to provide mechanical support and electrical insulation, allowing multiple layers to be wound without continuous decrease in available winding area.
Solution Approach 2:
Multiple layers of the second coil are nested vertically on the bobbin, with each layer properly insulated from the others. The support structures and insulating layers are nested within the winding configuration, maximizing space utilization while maintaining adequate winding area.
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 allows for increased turns in the second coil unit, ensures insulation between adjacent coils, and provides a compact arrangement with proper insulation distance, reducing the overall size and manufacturing costs while maintaining efficient operation.
Implementation Method 1
A transformer is an apparatus for changing voltage value or current value of AC (Alternating Current) by using electromagnetic phenomenon
Implementation Method 2
a core; a first coil unit wound on the core; a bobbin enclosing the first coil unit; and a second coil unit wound on the bobbin
Data Source
AI summary
A transformer including first coil unit and second unit, wherein one or more coils are wound on the bobbin of insulating material in at least one of the first coil unit and the second unit, and wherein the bobbin is formed with at least one partitioning flange for partitioning a coil winding surface of the bobbin into two winding surfaces along the longitudinal direction of the bobbin, is disclosed.