High-Frequency Transformer Bobbin Support Structure
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Solution Overview
Problem
Existing high-frequency transformers face challenges in being both small and capable of handling high currents due to the thinning of secondary windings, which compromises their ability to support the load on printed circuit boards, leading to potential overheating and instability.
Innovation Solution
A high-frequency transformer configuration featuring a pair of cores with legs forming a magnetic path, a primary winding and secondary winding wound around a bobbin with support portions that contact the printed circuit board, allowing for stable support and heat dissipation while maintaining a thin secondary winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the secondary winding is reduced to 0.2 mm to make the transformer smaller, then the transformer size is reduced, but the secondary winding cannot support the load on the printed circuit board due to decreased strength
Solution Approach 1:
The patent introduces a bobbin as an intermediary component between the secondary winding and the printed circuit board. The bobbin has support portions that extend to contact the PCB, transferring the load support function from the thin secondary winding to the bobbin. This allows the secondary winding to remain thin (0.2mm) for miniaturization while the bobbin provides the necessary mechanical strength for load support.
2Speed
If the secondary winding is made thinner to operate at high frequency (500 kHz), then the skin depth is reduced to 0.1 mm allowing thinner winding, but the transformer becomes difficult to support on printed circuit board
Solution Approach 1:
The bobbin serves as a mediator that decouples the high-frequency electrical function (performed by the thin secondary winding) from the mechanical support function (performed by the bobbin's support portions). This allows the system to operate at high frequencies with thin windings while maintaining reliable mechanical support through the bobbin-PCB contact structure.
3Temperature
If the secondary winding is configured as a thin copper plate to improve heat releasing, then heat dissipation is improved, but the winding strength decreases making it difficult to support the transformer
Solution Approach 1:
The bobbin acts as a structural intermediary that assumes the mechanical support role, allowing the secondary winding to be optimized for thermal performance (thin copper plate for heat dissipation) without compromising structural integrity. The bobbin's support portions provide the necessary strength while the thin winding provides efficient heat dissipation.
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 configuration enables a compact high-frequency transformer that effectively handles high currents and frequencies by providing stable support and efficient heat dissipation, preventing overheating and ensuring operational reliability.
Implementation Method 1
a primary winding 10 configured by electrical wires and a secondary winding 11 configured by a metal plate-shaped member... in order to provide a good magnetic coupling between the primary and secondary windings
Implementation Method 2
When the above-described transformer 5 is driven at a high frequency, an effective thickness of a metal plate used for a secondary winding is about twice the skin depth with respect to the frequency, taking into consideration the influence of a skin effect
Data Source
AI summary
A transformer is configured to include a pair of cores and that each have an inner leg, wherein a primary winding that is wound around a bobbin having a hollow into which the inner legs of the cores and are inserted, and a secondary winding that has a hollow into which the inner legs of the cores and are inserted and that is constituted of a conductor formed by die-cutting a metal plate into a ring, are dispersedly arranged over the inner legs of the cores and. The bobbin has bobbin support portions that come into contact with a surface of a printed circuit board on which the transformer is implemented.