High-Voltage Transformer Resin Bobbin Insulation
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Solution Overview
Problem
Conventional high-frequency transformers have complex configurations that complicate manufacturing and are prone to partial discharges when high voltage is applied, due to close proximity of primary and secondary windings.
Innovation Solution
A high-voltage and high-frequency insulation transformer with windings wound around resin bobbins having low dielectric constants, which are hermetically sealed with the same resin material, improving insulation and dielectric strength between high-voltage windings and cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If primary and secondary windings are wound one over another around a shared bobbin, then the transformer structure is compact, but insulation between windings deteriorates and partial discharge occurs under high voltage
Solution Approach 1:
The patent introduces a bobbin made of resin material with low dielectric constant as an intermediary structure between the primary and secondary windings. This bobbin physically separates the windings while maintaining electrical insulation, preventing partial discharge that would occur with direct winding-over-winding contact. The bobbin acts as a mediator that preserves both compactness and insulation reliability.
Solution Approach 2:
The patent changes the dielectric parameter of the insulation medium by using resin material with low dielectric constant for the bobbin, rather than traditional high-dielectric materials. This parameter change reduces electric field concentration and prevents partial discharge, improving insulation performance while maintaining the compact winding structure.
2Reliability
If insulating cover is added to improve insulation between ferrite core and winding, then insulation is improved, but device complexity increases
Solution Approach 1:
The patent merges the bobbin structure with the insulating function by making the bobbin itself from resin material that provides both mechanical support and electrical insulation. This integration eliminates the need for separate insulating covers between the ferrite core and windings, reducing component count while maintaining insulation reliability.
Solution Approach 2:
The resin bobbin serves multiple functions simultaneously: it provides mechanical support for the windings, electrical insulation between windings and core, and structural integration. This multi-functionality eliminates the need for separate insulating components, simplifying the overall device structure.
3Strength
If conventional insulating materials with high dielectric constant are used, then insulation strength appears high, but partial discharge inception voltage is low
Solution Approach 1:
The patent changes the dielectric constant parameter of the insulation material from high to low by using resin material. Although traditional high-dielectric materials show high insulation strength, they concentrate electric fields and cause partial discharge. The low-dielectric resin material distributes the electric field more evenly, raising the partial discharge inception voltage to 5.13 kV and improving high-voltage reliability.
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 solution enables easier manufacturing and significantly enhances dielectric strength, suppressing partial discharges and improving the transformer's ability to handle high voltages, as evident from a 5.13 kV partial discharge inception voltage compared to 1.90 kV in conventional structures.
Implementation Method 1
a bobbin formed of resin material having a low dielectric constant and high insulating properties
Data Source
AI summary
A transformer is configured to include a pair of cores that each have an inner leg, wherein a primary winding that is wound around a bobbin having a hollow into which the inner legs of the cores are inserted and that is hermetically sealed with resin material, and a secondary winding that has a hollow into which the inner legs of the cores are inserted and that is constituted of a conductor formed by die-cutting a metal plate into a ring are dispersedly arranged over the inner legs of the cores.