Transformer With Segmented Secondary Windings for Leakage Inductance Control
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Solution Overview
Problem
Conventional transformers face challenges in stabilizing leakage inductance, particularly in large-sized LCD televisions, due to increased magnetic path loops and inefficient winding configurations, which affect electric conversion efficiency and lead to thermal issues and increased costs.
Innovation Solution
The transformer design features plural single-trough secondary winding sections and an air gap over the primary winding coil, allowing for stable leakage inductance control, increased winding space, and reduced heat generation by optimizing the magnetic path and winding configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional winding configuration with secondary winding coil is used, then the transformer can be assembled, but the leakage inductance cannot be stably controlled due to increased magnetic path loops
Solution Approach 1:
The secondary winding is divided into multiple secondary winding sections instead of using a single continuous coil. Each section is independently wound around the bobbin, which segments the magnetic path and reduces the number of loops, thereby stabilizing the leakage inductance.
Solution Approach 2:
The winding structure transitions from a conventional single-layer configuration to a multi-dimensional arrangement where secondary winding sections are distributed around the bobbin body in different angular positions, optimizing the magnetic path geometry.
2Reliability
If protective tubes are used to cover outlet parts of winding coils, then the coils are protected from solder paste contamination, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
The protective tube component is completely removed from the design. Instead of using separate protective tubes, the outlet parts of the winding coils are directly exposed, and the design ensures that solder paste cannot reach the coil windings through proper positioning and spacing.
Solution Approach 2:
The transformer structure itself provides the protection function that was previously required from separate protective tubes. The bobbin structure and winding arrangement inherently prevent solder paste contamination, eliminating the need for additional protective components.
3Reliability
If protective tubes are used to cover outlet parts, then contamination is prevented, but thermal damage may occur and cost increases
Solution Approach 1:
The protective tube is removed entirely, eliminating the thermal damage risk and cost associated with this component while maintaining contamination prevention through structural design.
4Ease of manufacture
If conventional bobbin structure is used, then assembly is simple, but winding space is insufficient and heat generation is high
Solution Approach 1:
The bobbin structure incorporates multiple segmented winding sections that optimize the use of available space. The segmentation allows for better heat dissipation between sections while maintaining adequate winding space.
Solution Approach 2:
The bobbin design utilizes three-dimensional space more effectively by arranging winding sections in different angular positions and depths, maximizing the winding capacity without increasing the overall footprint.
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 electric conversion efficiency, reduces heat generation, and stabilizes leakage inductance, eliminating the need for protective tubes and minimizing assembly time and costs.
Implementation Method 1
A primary winding coil 111 and a secondary winding coil 112 are wound around the bobbin 11
Implementation Method 2
The magnetic core assembly 13 includes middle portions 131 and leg portions 132
Data Source
AI summary
A transformer includes a covering member, a bobbin, a primary winding coil, plural secondary winding coils, and a magnetic core assembly. The covering member includes plural pins. The bobbin is combined with the covering member, and includes a bobbin body and a channel. A first winding section and plural single-trough second winding sections are defined on the bobbin body. The single-trough second winding sections are arranged at bilateral sides of the first winding section. The channel runs through the bobbin body. The primary winding coil is wound around the first winding section of the bobbin, and connected with the pins. The secondary winding coils are wound around respective single-trough second winding sections of the bobbin. The magnetic core assembly is partially embedded into the channel of the bobbin.