Transformer Double Layer Coil Structure for Production Efficiency
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Solution Overview
Problem
Conventional transformer production processes face challenges in achieving a good connection between the primary supportive coil and the secondary main coil, leading to inefficiencies and increased production time due to the need for winding barrier tape around the secondary main coil.
Innovation Solution
A transformer design featuring a double layer structure with the secondary main coil wound around the outer peripheral of the primary main coil, allowing for improved insulation and eliminating the need for winding barrier tape, while also shortening the transformer's length and enhancing core strength by shifting the primary supportive coil vertically and winding it around a separate section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If barrier tape is wound around the outer peripheral of the secondary main coil to wind the primary supportive coil thereover, then good insulation between coils is achieved, but production time increases and workability deteriorates
Solution Approach 1:
The outer peripheral surface of the secondary main coil is divided into a first section and a second section separated by a groove. The primary supportive coil is wound around only the first section, while the second section remains exposed. This segmentation eliminates the need for barrier tape while maintaining proper insulation and magnetic coupling, significantly improving production efficiency.
2Device complexity
If the transformer uses a conventional single layer structure, then the structure is simple, but the transformer length increases and leakage flux increases
Solution Approach 1:
The patent transitions from a conventional single-layer horizontal winding structure to a double-layer vertical stacking structure. The primary main coil and secondary main coil are arranged in different layers with the secondary coil positioned above the primary coil, connected through a shared magnetic core. This dimensional change reduces the transformer length in the horizontal direction while maintaining electrical performance.
3Volume of moving object
If the primary supportive coil is positioned at the same level as the secondary main coil, then the structure is compact, but good connection between coils cannot be achieved
Solution Approach 1:
The primary supportive coil is positioned within the magnetic field region of the secondary main coil, with the groove on the secondary coil allowing the primary supportive coil to extend into the space above it. This nested arrangement ensures good magnetic coupling and electrical connection while maintaining a compact overall structure.
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 enhances workability during production, ensures secure insulation, improves productivity, and allows for a shorter transformer length, while suppressing leakage flux and preventing core damage from external impacts.
Implementation Method 1
Transformer according to the present invention comprises... primary main coil wound around said first hollow cylinder part, a primary supportive coil wound around said first section, and a secondary main coil wound around said second section
Data Source
AI summary
A transformer is provided having good workability during production and good connection of the secondary main coil and the primary supportive coil. The transformer has a bobbin with a base part and first hollow cylinder part with a first through hole and a core projecting in a first positive direction from said base part, and a case having an upper collar part formed with a primary main coil wound around said first hollow cylinder part, a second through hole leading to said first through hole, and a second hollow cylinder part formed at the outer peripheral face. Said primary main coil is housed and projects in a first negative direction from said upper collar part. A lower collar part opposes said base part by extending approximately parallel to said mounting face. The primary supportive coil and secondary main coil are wound around said first and second sections, respectively.