Transformer Core Penetration Through Holes Assembly
Solution Overview
Problem
Conventional transformers face challenges in reducing volume, simplifying structure, and reducing assembly time and cost, especially under high capacity and high current requirements, while also needing improved heat dissipation for small and thin electronic devices.
Innovation Solution
A transformer design featuring a first electrical conductor with a through hole and a second electrical conductor with spiral coils, both electromagnetically coupled with a core set that penetrates through holes in the conductors and a circuit board, allowing for efficient space utilization, heat dissipation, and reduced assembly time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of coils is increased to meet high capacity and high current requirements, then the transformer capacity is improved, but the assembly time and cost increase
Solution Approach 1:
Multiple wire cakes are integrated into a single bobbin structure, allowing multiple coils to be assembled simultaneously rather than individually. The bobbin serves as a common mounting platform that consolidates what would otherwise require separate assembly operations, directly reducing assembly time while maintaining the required number of coils for high capacity applications
Solution Approach 2:
The bobbin is designed to serve multiple functions: it provides structural support for multiple wire cakes, acts as an electromagnetic coupling medium, and serves as a mounting platform for all coils. This multi-functionality eliminates the need for additional components or assembly steps, reducing both assembly time and cost while maintaining transformer capacity
2Adaptability or versatility
If the transformer volume is reduced to meet small and thin electronic device requirements, then the adaptability is improved, but the heat dissipation capability deteriorates
Solution Approach 1:
The patent utilizes the axial dimension of the bobbin to arrange wire cakes in a stacked configuration, maximizing space utilization in the vertical direction. This allows the transformer to maintain a compact footprint (improving adaptability to small devices) while providing sufficient axial length for heat dissipation pathways, effectively decoupling volume reduction from heat dissipation degradation
3Ease of manufacture
If the transformer structure is simplified to facilitate assembling and application, then the ease of manufacture is improved, but the electromagnetic coupling efficiency may deteriorate
Solution Approach 1:
The bobbin is designed to simultaneously provide structural support, electromagnetic coupling, and alignment functions. By integrating these multiple functions into a single component, the structure is simplified for manufacturing and assembly while maintaining effective electromagnetic coupling between coils, as the bobbin's material properties ensure proper magnetic flux pathways
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 reduces assembly time and cost, enhances heat dissipation, and increases application efficiency by using a single conductive wire for spiral coils and integrating the core set with the conductors and circuit board for improved electromagnetic coupling.
Implementation Method 1
a first electrical conductor (31), a second electrical conductor (32), a core set (33) and a circuit board (34), wherein the first electrical conductor (31) is electromagnetically coupled with the second electrical conductor (32)
Data Source
AI summary
A transformer is provided. The transformer includes a first electrical conductor, a second electrical conductor, a circuit board and a core set. The first electrical conductor has a through hole and the second electrical conductor is electromagnetically coupled with the first electrical conductor and includes a plurality of spiral coils formed by winding a single conductive wire, each spiral coil having a through hole. The circuit board has a through hole. The core set penetrates the through hole of the first electrical conductor, the through hole of the circuit board, and the through holes of the plurality of spiral coils of the second electrical conductor, and covers at least one portion of the first electrical conductor and the second electrical conductor.