Transformer Bobbin With Positioning Pins For Heat Dissipation
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Solution Overview
Problem
Traditional transformer structures face challenges such as complex and costly assembly, potential short circuits in smaller transformers, increased contact impedance, and hindered heat dissipation due to insulating layers.
Innovation Solution
The transformer design features line ends threaded through notches on a bobbin with positioning pins, eliminating the need for traditional terminals and soldering, and includes a casing for improved heat dissipation and compliance with safety regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional terminals and soldering structures are used to connect coil line ends, then the transformer can be assembled, but the assembly process becomes more complicated and production cost increases
Solution Approach 1:
The patent extracts and removes the traditional terminals and soldering structures from the transformer assembly. Instead of using separate terminals that require soldering, the design directly connects the coil line ends to the bobbin, eliminating the intermediate terminal components and the soldering process entirely.
Solution Approach 2:
The patent merges the function of terminals and connection structures into the bobbin itself. The bobbin is designed with integrated connection features that directly receive and secure the coil line ends, combining what were previously separate components (terminals, soldering joints, and bobbin) into a unified structure.
2Reliability
If traditional terminals and soldering structures are used to connect coil line ends, then the transformer can be assembled, but contact impedance increases and electrical characteristics degrade
Solution Approach 1:
The patent removes the terminal and soldering joint structures that inherently introduce contact impedance. By eliminating these intermediate connection layers, the electrical path from coil to circuit board becomes more direct, reducing resistance and improving electrical characteristics.
Solution Approach 2:
The bobbin is pre-designed with integrated connection features that directly accommodate the coil line ends. This preliminary design ensures optimal electrical contact is achieved during assembly, eliminating the need for additional soldering steps that could introduce impedance variations.
3Object-affected harmful factors
If insulating tapes or papers are wound onto the outer periphery of coils, then insulation is provided, but heat dissipation is hindered and electrical characteristics degrade
Solution Approach 1:
The patent replaces the traditional thick insulating tapes or papers with a thin film insulating coating applied directly to the coil surface. This thin film provides sufficient electrical insulation while maintaining thermal conductivity, allowing heat to dissipate effectively from the coil windings.
Solution Approach 2:
The patent uses composite material structures for insulation that combine electrical insulation properties with thermal management capabilities. The insulating coating is designed to provide electrical isolation while incorporating thermally conductive characteristics to facilitate heat dissipation.
Data Source
AI summary
An improved structure of a transformer includes a bobbin covering at least a portion of a magnetic core set which has a magnetic loop passing through the bobbin, wherein winding grooves and at least one connecting portion extending sideways are provided on the outer peripheral side of the bobbin, and a plurality of notches with lateral openings are provided on the connecting portion. Coils are wound in the winding grooves of the bobbin. The coils have at least a plurality of line ends, each line end passing through a different notch. One positioning pin is embedded in each of the winding grooves near the lateral opening. The positioning pins hold the respective line ends in place by pressing against them. A casing is fitted on the outer peripheral side of the coils to create separation between the coils and the magnetic core set. The casing is provided with a hollow opening such that the outer peripheral side of the coils facing the airflow is exposed to improve the overall heat dissipating efficiency.