Transformer Side-Column Channel for Compact Lead Wire Routing
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Solution Overview
Problem
In switching power supplies, the compact arrangement of components is hindered by the need for lead wires of the primary side winding to be drawn out from the magnetic core, occupying space and limiting power density, while also risking interference with other components and inadequate heat dissipation.
Innovation Solution
A transformer design featuring a magnetic core with a through channel in one of its side columns allows the lead wire of the primary side winding to pass through, reducing space occupation and enhancing heat dissipation by providing a path for heat diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lead wire of the primary side winding is drawn out from the gap formed by the side column of the magnetic core, then the lead wire can be connected to external circuits, but the space occupation increases and power density decreases
Solution Approach 1:
The patent extracts the lead wire routing path from the external gap area and relocates it inside the magnetic core structure by creating a through channel in the side column. This allows the lead wire to pass through the magnetic core itself rather than being routed externally, thereby reducing the space occupied outside the magnetic core while maintaining electrical connectivity.
2Ease of operation
If the lead wire is drawn out from the gap formed by the side column, then the connection is established, but the safety distance from the secondary side winding must be maintained which further increases space occupation
Solution Approach 1:
The patent utilizes the vertical dimension of the magnetic core by creating a through channel that extends through the side column in the vertical direction. This allows the lead wire to pass through the magnetic core structure itself, utilizing the third dimension (height/depth) rather than requiring additional horizontal space, thereby maintaining safety distances without increasing the overall footprint area.
3Productivity
If the components are placed more compactly to improve power density, then space utilization improves, but the lead wire routing becomes more difficult and may cause interference with other components
Solution Approach 1:
The patent merges the lead wire routing function with the magnetic core structure itself by incorporating a through channel directly into the side column. This integration eliminates the need for separate external routing paths and reduces the complexity of lead wire installation, allowing for more compact component placement while maintaining clear, interference-free wire paths.
4Device complexity
If the lead wire is routed externally through the gap, then the structure is simple, but the heat dissipation capability is insufficient
Solution Approach 1:
The through channel in the side column acts as an intermediary thermal pathway. It provides a dedicated route for heat to conduct from the lead wire and primary winding area through the magnetic core structure to the external environment, enhancing heat dissipation capability while maintaining structural integrity and simplicity.
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 increases power density by compacting the transformer structure and improves heat dissipation, ensuring safe separation of lead wires and reducing interference with other components.
Implementation Method 1
heat generated in the operation of the transformer can be partially diffused to the outside of the transformer from the through channel, so that the heat dissipation capability of the transformer can be enhanced
Data Source
AI summary
The disclosure provides a transformer, a power module and a switching power supply. The transformer comprises a magnetic core, a primary side winding and a secondary side winding; the magnetic core comprises a first cover plate, a second cover plate, a winding column and at least two side columns, and at least two side columns of the magnetic core; at least one of the side columns has a through channel, the primary side winding is wound around the winding column, and a lead wire of the primary side winding passes through the through channel; the lead wire of the secondary side winding passes through a gap formed by the at least two side columns. In the disclosure, the lead wire of the primary side winding can pass through the through channel, thereby saving space and improving power density of the switching power supply.