Transformer Structure With Metal Sheet Coils
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Solution Overview
Problem
Existing transformers face issues with high power consumption and temperature rise, particularly in high-wattage power supplies, due to significant DC resistance.
Innovation Solution
A transformer structure featuring a winding stand with first and second coils, where the second coils are made of conductive metal sheets with ring bodies and pins, and an iron core set, designed to reduce DC resistance by optimizing coil arrangement and insulation, thereby reducing power consumption and temperature rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional wire-wound coils are used in high-wattage transformers, then the transformer can handle high power, but the DC resistance increases leading to high power consumption and temperature rise
Solution Approach 1:
The patent changes the fundamental parameter of coil construction from wire-wound to metal sheet wound coils. This parameter change reduces the DC resistance significantly while maintaining the power handling capability, thereby reducing power consumption and temperature rise in high-wattage transformers
Solution Approach 2:
The patent employs composite material structure by combining metal sheets with insulating coatings to create the coil windings. This composite approach allows achieving low DC resistance through the metal sheet configuration while the insulating coating provides necessary electrical insulation, resolving the contradiction between power handling and power consumption
2Power
If traditional wire-wound coils are used in high-wattage transformers, then the transformer can handle high power, but the temperature rise increases
Solution Approach 1:
The patent changes the fundamental parameter of coil construction from wire-wound to metal sheet wound coils. This parameter change reduces the DC resistance significantly while maintaining the power handling capability, thereby reducing power consumption and temperature rise in high-wattage transformers
3Loss of energy
If metal sheet wound coils are used to reduce DC resistance, then power consumption decreases, but the device complexity increases
Solution Approach 1:
The patent changes the fundamental parameter of coil construction from wire-wound to metal sheet wound coils. This parameter change reduces the DC resistance significantly while maintaining the power handling capability, thereby reducing power consumption and temperature rise in high-wattage transformers
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
The transformer structure effectively reduces power consumption and temperature rise by minimizing DC resistance, enhancing efficiency and compliance with high-efficiency regulations, such as the 80 PLUS model, while allowing for compact design in power electronics applications.
Implementation Method 1
a first coil, wound on the winding portion of the winding stand, and the first coil connects to the first pins electrically; two second coils, being two metal sheets having electrical conductivity, the two second coils are provided with a ring body and two second pins respectively, the two second pins being connected to the ring body, the two second coils being arranged on the side edge of the winding portion of the winding stand; and an iron core set, arranged on the winding stand, and the iron core set passes internally through the first coil and the two second coils
Data Source
AI summary
A transformer structure comprising a winding stand, a first coil, two second coils, and an iron core set. The first coil winds on the winding portion of the winding stand, and the first coil connects to the first pins electrically. The second coils are two metal sheets having electrical conductivity, the two second coils are provided with a ring body and two second pins respectively, the two second coils being arranged on the side edge of the winding portion of the winding stand. The iron core set is arranged on the winding stand, and the iron core set passes internally through the first coil and the two second coils. As a result, the DC resistance is decreased and the power consumption is reduced accordingly, improving the temperature rising problem.