Transformer With Metal Flap Secondary Winding
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Solution Overview
Problem
Existing transformer designs face challenges such as increased manufacturing complexity and cost due to the need for changing coil turns to alter output voltage, larger wire diameters leading to increased volume and eddy current loss, and limited flexibility in transformer design which affects competitiveness and efficiency.
Innovation Solution
The introduction of a removable and separable lead frame cover with a trouser-like flap secondary winding design that simplifies the manufacturing process, reduces production costs, and effectively minimizes magnetic leakage and copper loss by integrating a metal flap with wire connecting legs and clip-receiving recesses on the iron core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If coil type transformer with enamel covered wire is used for secondary winding, then it can satisfy low voltage and high current requirements, but the wire diameter must be larger which causes larger gap between turns, resulting in irrational volume increase and increased eddy current loss
Solution Approach 1:
The patent changes the physical form of the secondary winding from traditional enamel covered wire to a flat metal strip configuration. This parameter change in geometry allows the winding to maintain low voltage and high current capabilities while reducing the gap between turns, thereby decreasing eddy current loss and improving overall efficiency.
Solution Approach 2:
The invention uses a composite structure combining metal strip material with specific geometric configuration (flat profile with optimized dimensions). This composite approach replaces the traditional wire construction, enabling better current carrying capacity while minimizing eddy current effects through the altered material geometry and arrangement.
2Adaptability or versatility
If the number of turns of coil is changed to alter output voltage, then the transformer can adapt to different specifications, but the manufacturing process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent introduces a movable or adjustable component that allows the transformer to dynamically adapt to different output voltage specifications without requiring complete redesign or complex winding process changes. This dynamic element enables flexible voltage adjustment while maintaining a simplified manufacturing process.
Solution Approach 2:
The invention designs the transformer with a universal structure that can perform multiple voltage output functions through a single standardized manufacturing process. The metal strip secondary winding configuration allows for versatile voltage specifications to be achieved without complicating the core manufacturing steps, making the transformer adaptable to various applications.
3Power
If larger diameter conduction wire is used for secondary winding to satisfy low voltage and high current requirements, then the current capacity increases, but the overall volume of transformer irrationally increases
Solution Approach 1:
The patent changes the geometric parameters of the winding from circular cross-section wire to flat metal strip configuration. This parameter change in shape and dimensions allows the same current capacity to be achieved with reduced overall volume, as the flat strip format minimizes the space required while maintaining electrical performance for low voltage and high current applications.
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 transformer diversity and competitiveness by simplifying assembly, reducing losses, and achieving efficient current transfer while maintaining structural integrity.
Implementation Method 1
The relation for generating induction voltage depends on the secondary-to-primary-turn ratio
Implementation Method 2
each of the metal strips (8) has a hollow part (81) that is furnished at the center thereof, and is capable of slipping on the positioning parts (931) making all of the metal strips (8) axially stack up
Data Source
Figure 1
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AI summary
An improved structure of transformer includes a lead frame main body (1), a lead frame cover (2), a trouser-like flap (2), and two iron cores (4) where the lead frame main body has a penetration hole (11) with a bobbin (12) formed at the circumference there around. The trouser-like flap being made of metal has a hollow part (31) for slipping on a bobbin (121) of the lead frame main body also includes horizontally stretched thigh parts. The outer circumference of the trouser-like flap is furnished with a primary winding. The lead frame cover being a sheet-shaped body has a hollow hole (21) furnished at the center thereof. On the inner-side surface, each of the two iron core has a main core part (41) capable of stretching through the penetration hole of the lead frame main body where the main core part has a containing circumferential trench (43) capable of containing the lead frame main body. What is more, the containing circumferential trench also has a pair of oppositely disposed side openings (44, 45) for being stretched through by the wire connecting seats.