Transformer Bobbin Structure for Heat Dissipation and Warp Control
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Solution Overview
Problem
Existing power conversion apparatuses in eco-friendly vehicles face challenges in efficiently managing heat dissipation, substrate warping, and space utilization due to the integration of bulky transformers and components, leading to inefficiencies in thermal management and circuit design.
Innovation Solution
A power conversion apparatus design featuring a bobbin with recessed portions and protruded elements, coupled with a core and support members, along with a symmetric arrangement of components to minimize substrate warping, enhance heat dissipation, and optimize space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a bulky transformer is used in the power conversion apparatus, then the transformation function is achieved, but the substrate warps and structural stability deteriorates
Solution Approach 1:
A support member is introduced as an intermediary component between the bulky transformer and the substrate. This support member bears the weight and thermal load of the transformer, preventing direct contact that would cause substrate warping. The support member acts as a mediator that isolates the harmful effects of the transformer's mass and heat generation from the substrate while maintaining the transformer's functional position.
2Area of stationary object
If components are densely arranged to save space, then space utilization improves, but heat dissipation becomes insufficient
Solution Approach 1:
The design utilizes vertical space by extending heat dissipation fins in the vertical dimension rather than only horizontal expansion. The support member incorporates fins that protrude upward, creating a three-dimensional heat dissipation structure. This allows heat to be dissipated through multiple surfaces (top, sides, and bottom of fins) without increasing the horizontal footprint, effectively using the vertical dimension to enhance thermal management while maintaining compact horizontal space utilization.
3Area of stationary object
If asymmetric component arrangement is used, then space is saved, but substrate warping increases
Solution Approach 1:
The support member is designed with an asymmetric structure that intentionally compensates for the asymmetric arrangement of power conversion components. The support member's geometry, fin distribution, and positioning are asymmetrically configured to counterbalance the thermal and mechanical asymmetry introduced by the power conversion apparatus, thereby preventing substrate warping while maintaining compact asymmetric space utilization.
4Adaptability or versatility
If multiple heavy components are integrated, then functionality improves, but vertical vibration increases
Solution Approach 1:
The support member functions as a counterweight structure that balances the gravitational and vibrational forces of the integrated heavy components. By strategically positioning and dimensioning the support member with extended fins and increased mass distribution, it creates a counterbalancing effect that reduces the net vertical vibration transmitted to the substrate and housing, thereby mitigating the harmful vibrations caused by the integration of multiple heavy power conversion components.
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 minimizes substrate warping, improves heat dissipation through concentrated air circulation, and optimizes circuit design by integrating components symmetrically, enhancing thermal management and space efficiency.
Implementation Method 1
The power conversion apparatus switches the DC to create an alternating current (AC), which is then stepped up or down using components such as coils, transformers, and capacitors
Implementation Method 2
Afterward, it is rectified back into DC and serves to supply electricity at a voltage suitable for each electrical load
Data Source
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AI summary
A transformer according to an embodiment of the present invention comprises: a bobbin; a coil wound around the bobbin; and a core surrounding the coil and the bobbin, wherein the bobbin comprises an upper portion, a lower portion, and a middle portion which is between the upper and lower portions and around which the coil is wound, and holes are provided in the lower portion of the bobbin.