Vertical Transformer Core Bobbin Fixation
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Solution Overview
Problem
Conventional vertical transformers experience sound issues due to inadequate fixation methods between the core and bobbin, leading to vibration and potential damage, which compromises silent quality in electronic equipment.
Innovation Solution
A vertical transformer design featuring an adhesive hardened part connecting the core and bobbin with positioning projections and inclined surfaces, enhancing durability and adhesion strength while preventing sound emission and facilitating assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional fixation methods (adhering cores to each other, winding tape, adhering core and bobbin at opposing faces) are used, then assembly is simple, but sound suppression is insufficient and mechanical durability is poor
Solution Approach 1:
The fixation structure is divided into multiple functional elements: positioning projections on the core, corresponding positioning recesses on the bobbin, and adhesive application areas. This segmentation allows each element to perform its specific function (positioning, alignment, bonding) effectively, achieving superior sound suppression without excessive overall complexity
Solution Approach 2:
Positioning projections and recesses are pre-formed on the core and bobbin respectively before assembly. This preliminary action ensures accurate positioning and alignment is achieved automatically during assembly, eliminating the need for complex adjustment mechanisms and reducing overall fixation structure complexity
2Reliability
If adhesive is applied only at opposing faces of core and bobbin, then manufacturing is simple, but mechanical endurance under vibration is insufficient
Solution Approach 1:
Adhesive is applied selectively at specific locations where positioning projections contact the bobbin, rather than uniformly across entire opposing faces. This local quality approach concentrates bonding strength at critical stress points, significantly improving mechanical endurance under vibration while reducing overall adhesive usage and application complexity
3Strength
If core and bobbin are adhered at opposing faces, then assembly is straightforward, but cracks occur when bobbin strength is low
Solution Approach 1:
Positioning projections act as intermediary elements between the core and bobbin, distributing bonding stresses across multiple contact points rather than concentrating them at opposing faces. This intermediary mechanism protects low-strength bobbins from cracking while achieving superior bond strength, without requiring complex fixation structures
Solution Approach 2:
The positioning projections and recesses are designed to cushion and distribute mechanical stresses before they can concentrate and cause cracks in the bobbin. This beforehand cushioning effect protects vulnerable components during assembly and operation, enabling reliable bonding even when bobbin strength is low
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 proposed design effectively suppresses sound and improves mechanical endurance, allowing for the use of materials with lower strength and simplifying manufacturing, while ensuring secure fixation and accurate positioning of components.
Implementation Method 1
an adhesive hardened part connecting a connection side face and the core on-board face, where the connection side face is a face of the first connection part extended in order to intersect with the core on-board face, and formed by hardening an adhesion
Data Source
AI summary
A vertical transformer comprising a core provided with a middle leg installing a first and a second coils, a side leg, a first connection part connecting an end of the middle leg and that of the side leg, and a second connection part connecting the other end of the middle leg and that of the side leg, a first bobbin provided with a first hollow cylinder where at least either the first or the second coil is wound, and a core on-board face connected to an end of the first hollow cylinder, and an adhesive hardened part connecting a connection side face, and the core on-board face, and formed by hardening an adhesion, wherein the core on-board face is provided with a positioning part positioning the connection side face, and a positioning projection, is formed on both sides of the first connection part.