Welding Transformer Coil Insulation for Dust-Prone Terminals
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Solution Overview
Problem
Welding transformers face short-circuiting issues due to dust accumulation between terminals, which existing designs fail to adequately prevent.
Innovation Solution
A welding transformer design featuring unit coils with extended terminal portions and insulating sheets that extend along the coil surfaces and pass through spaces between terminals, reducing the likelihood of short-circuiting by increasing insulation distance and using folded insulating sheets to enhance separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If terminals are extended side by side for connection, then electrical connection is facilitated, but the space between terminals becomes a pathway for dust accumulation causing short-circuits
Solution Approach 1:
The folded insulating sheet acts as an intermediary element that fills and seals the space between the extended terminals. This intermediary barrier prevents dust particles from entering and accumulating in the terminal region, while the terminals remain extended and accessible for electrical connection purposes.
2Reliability
If insulating sheets completely cover the coil, then insulation is maximized, but the sheets become bulky and difficult to assemble
Solution Approach 1:
The insulating sheet is segmented into functional regions: a main body portion that wraps the coil and folded portions that pass through the terminal space. This segmentation allows the sheet to provide comprehensive insulation coverage while maintaining a flat, manageable structure that is easy to assemble, avoiding the need for bulky three-dimensional forms.
Data Source
AI summary
A copper plate that forms a primary-side unit coil has a body portion, a first terminal portion, and a second terminal portion. A first insulating sheet has a first insulating portion and a second insulating portion. The first insulating portion extends along a surface of the body portion. The second insulating portion passes through a space between the first terminal portion and the second terminal portion.