Transformer Winding Structure with Extending Sections for Heat Dissipation
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Solution Overview
Problem
Conventional transformer structures face challenges with insufficient space due to increased power output, leading to crowded circuit boards and high-frequency copper wire losses, as well as heat-dispersion issues caused by the greenhouse effect of copper wire frames.
Innovation Solution
The transformer design features a secondary winding coil with extending sections that cross-connect to the circuit board, reducing the need for extensive copper foil and enhancing heat dissipation by increasing air contact, allowing for more efficient use of space and lower resistance to high-frequency currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional copper foil is used to connect transformer to circuit board, then electrical connection is achieved, but circuit board space is occupied and arrangement becomes complicated
Solution Approach 1:
The extending section of the secondary winding coil extends outward perpendicular to the circuit board plane, utilizing the third dimension (Z-axis) to conduct electricity. This eliminates the need for wide copper foils on the circuit board surface, freeing up valuable board space and simplifying element arrangement.
Solution Approach 2:
The electrical connection function is extracted from the circuit board plane and moved to the vertical extending section. The extending section is separated from the traditional copper foil connection method, allowing the circuit board to be used more efficiently for mounting electronic elements.
2Temperature
If copper wire frame is used to wind transformer, then electrical connection is achieved, but heat dissipation is blocked due to greenhouse effect
Solution Approach 1:
The extending section extracts the electrical connection function from the enclosed copper wire frame structure. By extending outward and making contact with the circuit board from the outside, it creates an opening that breaks the greenhouse effect and enables heat to escape from the transformer interior.
Solution Approach 2:
The extending section creates a porous or open structure in the transformer winding assembly. This allows heat pathways to form through the previously enclosed space, improving thermal dissipation while maintaining electrical functionality.
3Loss of energy
If high frequency current passes through copper wire, then electrical conduction is achieved, but resistance increases due to skin effect
Solution Approach 1:
The extending section acts as a complementary conductor that works in parallel with the copper wire frame. This creates multiple current pathways, effectively reducing the overall resistance and mitigating the skin effect losses by distributing high frequency current across different conduction paths.
4Power
If power output is increased to meet high power requirements, then power supply capability is improved, but transformer size and element size are enlarged
Solution Approach 1:
The extending section utilizes vertical space perpendicular to the circuit board to conduct high currents. This three-dimensional current path allows for higher power transmission without proportionally increasing the footprint area on the circuit board, enabling compact high-power transformer designs.
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 optimizes space usage on the circuit board, reduces copper foil requirements, and improves heat dissipation, thereby increasing the number of electronic elements that can be mounted and lowering the working temperature and resistance of the transformer.
Implementation Method 1
the extending section can further increase the connect area with the air for achieving a heat-dispersing effect
Data Source
AI summary
The present invention discloses that a primary and a secondary winding coil are respectively wound around the core and are separated by an insulating layer; and the secondary winding coil has a winding portion wound around the core through at least a circle to define two winding terminals, wherein each winding terminal of the winding portion is connected with an extending section extended to the outside of the transformer and is connected with an electricity connecting section at the rear end thereof. The electricity connecting section has plural pins electrically welded on a circuit board, thereby the extending section that is connected with a rectification switch and increases the contact areas with the air for achieving a heat-dispersing effect and the electricity connecting section are crossing connected between the secondary winding coil and the circuit board to save the space on the circuit board for arranging the secondary winding coil.