Transformer Winding Unit Planar Arrangement for Compact Design
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Solution Overview
Problem
Conventional transformers face challenges in miniaturization, assembly complexity, heat dissipation, and increased dimensions due to the use of insulating tapes, which can lead to reduced lifespan and inductance leakage.
Innovation Solution
A transformer design featuring a ferromagnetic core, bobbin with recess and pin, and conductive wire wound on a single plane, with a sandwiched structure using plates and insulating sheets to reduce dimensions, prevent sliding, and enhance heat dissipation, while maintaining easy assembly and preventing short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating tape is wound around the primary winding, then electrical insulation is provided, but the transformer dimension increases and assembly becomes complicated
Solution Approach 1:
The insulating function is merged into the bobbin structure itself. The bobbin is designed with an insulating layer integrated into its body that directly contacts the primary winding, eliminating the need for separate insulating tape. This reduces assembly steps and simplifies the overall structure while maintaining electrical insulation.
Solution Approach 2:
The insulating tape component is extracted and removed from the transformer structure. Instead of using separate insulating tape, the bobbin is designed to provide the necessary insulation function through its own structure, thereby eliminating the need for additional insulating components and simplifying assembly.
2Reliability
If insulating tape is used for winding insulation, then electrical isolation is achieved, but heat dissipation is obstructed and transformer lifespan is shortened
Solution Approach 1:
The material parameters of the bobbin are changed to provide both electrical insulation and thermal conduction. The bobbin is designed with materials or structures that maintain electrical isolation properties while having high thermal conductivity to facilitate heat dissipation from the windings, thereby preventing heat accumulation and extending transformer lifespan.
3Adaptability or versatility
If conductive wire is wound on multiple planes, then winding flexibility is increased, but transformer dimension increases
Solution Approach 1:
The winding structure transitions from multi-planar arrangement to a single-plane configuration. The conductive wire is wound on a single plane of the bobbin, and the bobbin's three-dimensional structure provides the necessary flexibility and routing capabilities, thereby reducing the transformer's overall dimension while maintaining winding adaptability.
4Stability of the object's composition
If rib and bobbin are press-fitted to prevent sliding, then structural stability is improved, but assembly difficulty increases
Solution Approach 1:
The rib structure is designed with asymmetric geometry that provides stable press-fit connection while facilitating assembly. The rib has a tapered or asymmetric cross-section that guides it into the corresponding groove during assembly, providing structural stability through the press-fit connection while the asymmetric shape itself aids in alignment and insertion, reducing assembly difficulty.
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 design results in a compact, efficient transformer with improved heat dissipation and reduced dimensions, preventing inductance leakage and extending the transformer's lifespan by simplifying assembly and preventing unintentional wire damage.
Implementation Method 1
The conductive wire, such as a triple-insulated wire or an enamel-insulated wire, is wound substantially on the same plane to reduce dimension of the transformer
Implementation Method 2
the rib and the bobbin are press-fitted in order to eliminate excessive strain and to prevent sliding therebetween
Implementation Method 3
The primary winding receives an input voltage, and the secondary winding generates an output voltage by electromagnetic induction from the primary winding
Data Source
AI summary
Transformers are provided. A transformer comprises a ferromagnetic core unit; a bobbin coupled with the ferromagnetic core unit; at least a winding unit as a primary winding and at least a plate as a secondary winding. Also, some of the winding units can act as a secondary winding. At least a winding unit and at least a plate are alternatively stacked in a staggered manner. A conductive wire is wound around the winding unit.