U-Shaped Core High-Voltage Transformer Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Developing high-voltage transformers with small dimensions that maintain high power density and reliability, while minimizing manufacturing costs and parasitic inductances, is challenging due to the need for compact designs that balance magnetic core geometry, winding configurations, and compatibility with mobile and lighting applications.
Innovation Solution
A high-voltage transformer with a U-shaped core and three or more turns in the primary winding, where the windings are applied to one leg of the core, allowing for efficient manufacturing and reduced parasitic inductances, and a compact structure that achieves desired inductance and oscillation behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the transformer size is reduced to achieve compact design, then the volume and weight are reduced, but the power density and reliability may be compromised
Solution Approach 1:
The patent changes the geometric parameters of the magnetic core, specifically using a U-shaped core with optimized leg dimensions and a specific yoke thickness. This allows achieving compact volume while maintaining the magnetic path length and cross-sectional area necessary for reliable high-voltage operation. The core dimensions are carefully selected to balance volume reduction with maintaining adequate magnetic properties for reliability.
2Volume of moving object
If the number of primary turns is reduced to fewer than 3, then the construction volume is reduced, but the inductance and oscillation behavior are adversely affected
Solution Approach 1:
The patent establishes that the primary winding must have at least 3 turns to achieve the desired inductance value and oscillation behavior. This parameter specification ensures that the transformer produces the required electrical characteristics while maintaining compact dimensions. The minimum turn requirement is derived from optimizing the balance between volume and electrical performance.
3Device complexity
If the core length is increased to improve magnetic properties, then the inductance is improved, but the overall dimensions and volume increase
Solution Approach 1:
The patent employs an asymmetric U-shaped core design where the two legs have different dimensions. One leg is optimized for magnetic flux path while the other is optimized for winding accommodation and heat dissipation. This asymmetric configuration allows achieving good magnetic properties without proportionally increasing the overall core length, as the magnetic path is efficiently utilized within the available space.
Solution Approach 2:
Instead of increasing core length in one dimension, the patent optimizes the core cross-sectional dimensions and yoke thickness. By adjusting the dimensional distribution across different axes (width, height, thickness) rather than simply extending length, the magnetic properties are improved while keeping the overall footprint and volume constrained.
4Ease of manufacture
If standard ferrite cores are used, then manufacturing is simplified, but the precision control of inductance and oscillation behavior is limited
Solution Approach 1:
The patent specifies precise parameter ranges for the U-shaped core dimensions, including leg lengths, widths, and yoke thickness, to achieve the desired inductance and oscillation characteristics. By defining these geometric parameters within specific ranges, the patent enables precision control of electrical properties while maintaining compatibility with standard manufacturing processes for ferrite cores. The optimized dimension specifications allow standard cores to be selected or manufactured with controlled tolerances.
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 a compact, high-voltage transformer with improved power density, reduced manufacturing costs, and controlled oscillation behavior, suitable for applications like gas discharge lamps and mobile devices, while maintaining mechanical and thermal properties.
Implementation Method 1
a first winding (140) with three or more turns (141, 142, 143)... a second winding (120)... U-shaped core (110)... transforms an input voltage of several 10 V to several 100 V to a relatively high output voltage
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3C
AI summary
The transformer of the invention comprises a first coil that has three or four windings, preferably exactly three windings, a second coil, and a U-shaped core. The length of the transformer is 40 mm or less, resulting in a compact volume, for example for ignition units of luminaires, and production costs are reduced because a U-shaped core is used.