Insulating Slipcase for Transformer Core Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional transformers face safety issues due to exposed magnetic cores, which can lead to electrical hazards, especially in high-density electronic devices, and require unstable and labor-intensive insulation methods, making them unsuitable for portable devices and increasing fabrication costs.
Innovation Solution
A transformer design featuring an insulating slipcase that encases the magnetic core and bobbin, providing enhanced electrical insulation and protection against short circuits, with a simple construction that reduces fabrication complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the transformer is designed with exposed magnetic core to reduce size, then the device size is reduced, but the electrical safety is compromised due to proximity to other components
Solution Approach 1:
An insulating housing is introduced as an intermediary component between the magnetic core and other electronic components. The housing encloses the magnetic core and bobbin, providing electrical insulation while allowing the transformer to maintain a compact size suitable for high-density device arrangements.
2Object-affected harmful factors
If insulating tape is used to seal the exposed magnetic core, then electrical insulation is provided, but the insulation stability becomes unreliable and labor-intensive
Solution Approach 1:
Instead of using flexible insulating tape that can detach or fail, a rigid insulating housing is employed to enclose the magnetic core. This housing provides stable, reliable insulation that cannot be inadvertently displaced during assembly or device use, eliminating the reliability issues associated with tape-based solutions.
3Object-affected harmful factors
If insulating tape is manually attached to the magnetic core, then electrical insulation is achieved, but the fabrication complexity and cost increase
Solution Approach 1:
The insulating housing is designed to integrate multiple functions: it provides electrical insulation, mechanically supports the bobbin, and serves as a protective enclosure. This consolidation eliminates the need for separate manual taping operations, simplifying the manufacturing process and reducing labor costs.
4Productivity
If the transformer components are placed in high density, then more components can be accommodated, but the exposed magnetic core creates safety risks due to proximity to other components
Solution Approach 1:
The insulating housing serves multiple purposes simultaneously: it enables high-density packaging by providing built-in insulation that eliminates clearance requirements for exposed magnetic cores, maintains electrical safety through enclosed design, and provides mechanical support for the bobbin structure.
Data Source
AI summary
A transformer and a method of manufacturing the same are disclosed. The transformer comprises a magnetic core, a winding coil with a primary winding coil and a secondary winding coil, a bobbin with a primary input port and a bobbin connecting member, and an insulating slipcase. The bobbin is mounted by the winding coil. The insulating slipcase includes a first opening to receive the magnetic core, the winding coil and the bobbin, and includes a first side wall, a second side wall with a slipcase connecting member which is engaged with the bobbin connecting member, and a secondary output port for dealing with the output of the transformer. The first side wall is opposite to the first opening and has a second opening for the output of the secondary winding coil.