Transformer Bonding via Outer Leg Insertion in Lighting Devices
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Solution Overview
Problem
The challenge lies in bonding a circuit board with a sheet transformer to a base in lighting devices, as the miniaturization and thinning of components make it difficult to secure the transformer effectively, leading to issues with assembly and potential deterioration due to mechanical stress.
Innovation Solution
The solution involves a lighting device design where the circuit board has specific insertion portions for the transformer's leg portions, allowing for the use of resin to bond the transformer's outer and central leg portions to the base, creating an air gap and facilitating easy assembly while preventing mechanical stress on the transformer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circuit board with a sheet transformer is bonded directly to a base, then the structure appears simple, but it becomes difficult to bond the circuit board and base together due to miniaturization and thinning of components
Solution Approach 1:
The patent introduces an intermediary structure (the core with outer leg portions) between the circuit board and base. The outer leg portions extend through the circuit board and are inserted into insertion portions on the base, serving as a mediator that enables bonding. The resin is applied to bond the outer leg portions to the base, solving the bonding difficulty without requiring direct circuit board-to-base bonding.
Solution Approach 2:
The patent utilizes the vertical dimension by having the outer leg portions extend through the circuit board in the thickness direction. This dimensional approach allows the leg portions to reach the base and form bonding points, transforming a 2D bonding problem into a 3D solution that overcomes the thinning of the circuit board.
2Volume of moving object
If the circuit board is made thinner to reduce device size, then miniaturization is achieved, but bonding to the base becomes more difficult
Solution Approach 1:
The transformer is segmented into a winding pattern on the circuit board and a separate core with outer leg portions. The outer leg portions are extended through the circuit board to create bonding points on the base, allowing the thin circuit board to still achieve secure bonding through these extended segments.
3Reliability
If resin is used to bond the transformer leg portions to the base, then secure bonding is achieved, but the assembly process becomes more complex
Solution Approach 1:
The outer leg portions are pre-formed as part of the transformer core structure before assembly. This preliminary formation of the leg portions allows for straightforward insertion into the base and subsequent resin bonding, simplifying the overall assembly process while ensuring reliable bonding.
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 enables easy and precise bonding of the circuit board and base, reducing the risk of transformer deterioration and improving assembly efficiency, while maintaining transformer performance even in high-temperature environments.
Implementation Method 1
the base and at least a lateral face of the outer leg portion are bonded together by a first resin that is insertable from the outer leg insertion portion
Data Source
AI summary
A lighting device includes: a circuit board placed on a base; and a transformer provided in the circuit board. The transformer includes: a winding pattern formed on the circuit board; and a core having an outer leg portion. The circuit board has an outer leg insertion portion through which the outer leg portion of the core is inserted, and the circuit board and the base have therebetween a gap which is air space. The base and at least a lateral face of the outer leg portion are bonded together by a first resin that is insertable from the outer leg insertion portion.