Small Transformer Design Removing Cover Sidewalls
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Solution Overview
Problem
Conventional small size transformers face challenges in further size reduction due to the occupied space by sidewall portions of the cover member, which hinder the achievement of high insulation performance and compact design.
Innovation Solution
The design incorporates a hollow bobbin with flange parts, a box-shaped cover member, and a dual-compartment magnetic core, where the conducting wire is made of reinforced insulation wire, and the sidewall portions of the cover member are eliminated to allow close-contact between the bobbin's outermost circumferential portion and the core member's inner wall, ensuring high insulation without the need for sidewall interposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sidewall portions of the cover member are provided to ensure insulation between the wiring part and core part, then insulation performance is improved, but the transformer size in the cross direction increases
Solution Approach 1:
The patent removes the sidewall portions of the cover member that were previously used for insulation, extracting only the essential insulating function and implementing it through alternative means (insulating paint or insulating film) applied directly to the bobbin, thereby reducing the cross-direction length while maintaining insulation performance
Solution Approach 2:
The patent changes the insulation implementation from a structural component (sidewall portions) to a surface treatment (insulating paint or film), fundamentally altering how insulation is achieved and enabling size reduction in the cross direction
2Reliability
If the cover member includes sidewall portions to provide insulation, then insulation is ensured, but the overall transformer volume increases
Solution Approach 1:
The patent extracts the insulating function from the cover member's sidewall portions and implements it through minimal surface treatment on the bobbin, eliminating unnecessary volume while preserving the essential insulation function
Solution Approach 2:
The patent employs thin insulating films or paint coatings on the bobbin surface instead of bulky sidewall structures, achieving the same insulation effect with minimal material and volume
Data Source
AI summary
A small size transformer is provided with hollow bobbin which has flange-shaped end parts at least on both ends of winding shaft part around which conducting wire formed of reinforced insulation wire is wound, and is formed by through-hole being pierced between the flange parts, box-shaped cover member to be covered on an outside of the bobbin, and magnetic core part formed by combining two E-shaped core members in a manner of surrounding side surface outer circumferential part of cover member, in which middle leg portions of the core members are configured in a manner of being inserted into the through-hole of the bobbin, in which sidewall parts of cover member to be interposed between the wiring part wound around bobbin and the core members are not provided therebetween.