Transformer Mounting Insulation via Lateral Protrusion
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Solution Overview
Problem
Conventional transformer mounting technologies face challenges in maintaining a sufficient insulation distance between primary and secondary terminals while minimizing the mounting area, which can lead to increased space requirements under the substrate and complicates the mounting process.
Innovation Solution
The electronic device incorporates a substrate with primary and secondary terminal holes and a slit, where an insulating member with a protrusion portion is inserted from the opposite surface, extending beyond the terminal ends to ensure insulation distance and stability, allowing for compact transformer mounting without space constraints under the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the mounting area of the transformer is reduced, then the terminal distance between primary side terminals and secondary side terminals is reduced, but the insulation distance becomes insufficient
Solution Approach 1:
The insulating member extends not only in the vertical direction (downward from the mounting surface) but also in the lateral direction (horizontal direction) beyond the extension lines of the slit. This two-dimensional extension approach ensures that the insulation distance is maintained even when the terminal distance is reduced due to smaller mounting area.
Solution Approach 2:
An insulating member is introduced as an intermediary element between the primary side terminals and secondary side terminals. This insulating member includes a protrusion portion that extends laterally beyond the slit boundaries to provide additional insulation, acting as a mediator that ensures sufficient insulation distance without requiring larger terminal separation.
2Reliability
If a longer wall-shaped insulating portion is used to maintain insulation distance, then the insulation distance is sufficient, but large mounting space is required under the substrate
Solution Approach 1:
Instead of extending the insulating member only in the vertical direction (which would increase space under the substrate), the insulating member is designed to extend in both vertical and lateral directions. The protrusion portion extends horizontally beyond the slit boundaries, providing the necessary insulation distance without requiring excessive vertical space under the substrate.
Solution Approach 2:
The insulating member has different functional regions: a wall-shaped portion for vertical insertion into the slit and a protrusion portion for lateral extension beyond the slit. This local differentiation allows the insulating member to provide sufficient insulation distance while minimizing the space required under the substrate, as the protrusion portion extends horizontally rather than vertically.
3Area of moving object
If the terminal distance is reduced to minimize mounting area, then the transformer size is reduced, but the mounting process becomes more difficult
Solution Approach 1:
The insulating member with its protrusion portion serves as a mediator that facilitates the mounting process. By providing a clear lateral boundary (the protrusion portion extending beyond the slit), it guides the positioning of the transformer relative to the substrate, making the mounting process easier even when terminal distances are reduced.
Solution Approach 2:
The insulating member is designed with a predetermined protrusion portion that extends beyond the slit boundaries before mounting. This preliminary structural feature establishes clear positioning references that guide the mounting process, making it easier to align the transformer correctly on the substrate without requiring complex alignment procedures.
Data Source
AI summary
A substrate includes primary side terminal holes into which the primary side terminals are inserted, secondary side terminal holes into which the secondary side terminals are inserted, and a slit disposed between the primary side terminal holes and the secondary side terminal holes. A transformer is mounted from the side of a mounting surface of the substrate. An insulating member is inserted into the slit from the side of a soldering surface of the substrate. The insulating member includes a protrusion portion that protrudes outside an area defined by virtual lines which are direct extension lines of the width of the slit to the side of the soldering surface. The protrusion portion is formed at a position more distant from the substrate than an end position of the shortest terminal of the primary side terminals and the secondary side terminals from the soldering surface of the substrate.