Transformer Drum Core with Dual-Stage Gap Structure
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Solution Overview
Problem
Conventional transformers experience eddy-current losses and unstable output voltage due to magnetic saturation and stray capacitance issues, particularly in high transformer ratio applications.
Innovation Solution
A transformer design featuring a drum core with a plate-like core and strategically formed gaps to inhibit magnetic flux between terminal electrodes, along with winding configurations that separate the primary and secondary winding start portions to reduce stray capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gap is provided between the plate-like core and the flange to suppress magnetic saturation, then DC superposition characteristic is improved, but magnetic flux passes between the plate-like core and terminal electrode causing eddy current loss
Solution Approach 1:
The plate-like core is designed with differentiated local structures: a first opposing portion without terminal electrodes and a second opposing portion with terminal electrodes. This local differentiation allows the first gap to be optimized for magnetic flux suppression while the second gap addresses eddy current prevention specifically at electrode locations.
Solution Approach 2:
The gap structure is segmented into two distinct types: first gaps formed by spacers between the top face and first opposing portion, and second gaps formed by recesses between terminal electrodes and the second opposing portion. This segmentation enables independent optimization of each gap's function.
2Power
If the secondary winding is wound in multiple tiers with high turn ratio to achieve high transformer ratio, then step-up capability is improved, but stray capacitance between primary and secondary windings increases causing unstable output voltage
Solution Approach 1:
The winding arrangement utilizes the axial dimension of the drum core by positioning winding start portions at different axial locations. This dimensional separation effectively reduces the spatial overlap between primary and secondary windings, thereby reducing stray capacitance while maintaining high turn ratio capability.
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 improves DC superposition characteristics without eddy-current losses and stabilizes output voltage by controlling magnetic flux and capacitance, enhancing the transformer's performance in step-up applications.
Implementation Method 1
magnetic fluxes pass between the top face and the first opposing portion where the first gap is formed
Implementation Method 2
Two windings (primary and secondary windings) are wound, for example, one by one as lower and upper tiers, about each winding groove (winding core part)
Implementation Method 3
a gap may be provided between the plate-like core and the flange so as to suppress the magnetic saturation
Implementation Method 4
terminals of the windings are connected to their corresponding electrodes
Data Source
AI summary
A transformer that improves the DC superposition characteristic without incurring eddy-current losses. In the transformer, a part of a plate-like core opposing a top face of a flange of a drum core is formed with a first opposing portion opposing none of input and output terminals and a second opposing portion opposing the input and output terminals. A first gap is formed between the top face and the first opposing portion by a spacer. A second gap greater than the first gap is formed by a recess of the plate-like core provided so as to correspond to the second opposing portion. This allows magnetic fluxes to pass between the top face and the first opposing portion where the gap is formed and inhibits them from passing between the plate-like core and the input and output terminals where the second gap greater than the first gap is formed.