Transformer With Separated Magnetic Members
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Solution Overview
Problem
Current transformer assembly manufacturing techniques result in residual air gaps due to the difficulty of adhesive material flowing into complex geometries, leading to breakdowns at low voltages, mechanical instability, and increased manufacturing costs.
Innovation Solution
A transformer device manufacturing process that positions insulation material within the substrate layer orifice before complex geometries form, followed by adhesive layers and magnetic members, ensuring that viscous materials like mold compounds can fill spaces without air gaps, thereby eliminating opportunities for air gap formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If adhesive material is applied to fill spaces between magnetic members and substrate layer, then mechanical stability is improved, but residual air gaps form due to complex geometries
Solution Approach 1:
The patent applies adhesive material to the bottom surface of the substrate layer before placing the magnetic members, ensuring that the adhesive is already in position to fill spaces as the magnetic members are added, rather than trying to flow adhesive into complex geometries afterward
Solution Approach 2:
The patent divides the adhesive application into multiple stages: first applying adhesive to the substrate layer bottom surface, then applying additional adhesive between magnetic members after assembly, allowing each adhesive application to target specific spaces without the complexity of filling all geometries at once
2Manufacturing precision
If multiple curing steps are used to manufacture transformer assembly, then manufacturing precision is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent performs adhesive application in advance at simplified stages (substrate preparation and magnetic member assembly) rather than attempting to fill all complex geometries in a single difficult step, reducing the need for multiple curing operations
Solution Approach 2:
The patent extracts the adhesive filling problem from the complex internal geometries and addresses it at simpler external surfaces (bottom of substrate layer and gaps between magnetic members), where adhesive application and curing is more straightforward
3Manufacturing precision
If adhesive material flows into complex geometries, then manufacturing precision is improved, but air gaps remain due to material viscosity
Solution Approach 1:
The patent applies adhesive to the bottom surface of the substrate layer before assembling magnetic members, allowing the adhesive to settle and begin curing in a simple geometry where complete filling is easier to achieve, rather than relying on viscous material to flow into complex internal spaces
Solution Approach 2:
The patent addresses space filling in segmented stages: first filling the substrate layer cavity with adhesive before magnetic member assembly, then filling gaps between magnetic members with additional adhesive, breaking down the complex filling problem into manageable segments
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 process significantly reduces or eliminates air gaps in transformer devices, enhancing reliability, efficiency, and longevity by preventing air gap-related issues and simplifying the manufacturing process.
Implementation Method 1
transformer coils encircling a third magnetic member
Implementation Method 2
first magnetic member; a second magnetic member... third magnetic member inside the substrate layer
Data Source
AI summary
In examples, a transformer device comprises a first magnetic member; a second magnetic member; and a substrate layer between the first and second magnetic members. The substrate layer comprises a transformer coil. The transformer device includes a third magnetic member inside the substrate layer. The transformer coil encircles the third magnetic member. The third magnetic member physically separates from the first and second magnetic members.