Copper-Sheet Transformer Winding Layout for Compact PCB Integration
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Solution Overview
Problem
Conventional transformers face challenges in reducing size, improving power density, and matching layout requirements due to fixed spacing between windings in integrated magnetic cores, limiting their ability to adapt to different PCB layouts and affecting efficiency and thermal performance.
Innovation Solution
A transformer structure with secondary windings formed by copper sheets of different types, stacked and arranged around magnetic core legs with varying terminal distances and orientations, allowing for customizable winding spacing and improved thermal performance, and incorporating insulating films and epoxy boards to enhance efficiency and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional integrated magnetic core structures are used with fixed winding spacing, then manufacturing is simplified, but adaptability to different PCB layouts is poor
Solution Approach 1:
The transformer winding structure is segmented into multiple independent winding units, each comprising primary windings and secondary windings that can be independently configured. Each winding unit includes insulating films and magnetic cores that are divided into separate modules, allowing flexible assembly and adaptation to different PCB layouts without requiring complete redesign of the entire transformer structure.
Solution Approach 2:
The transformer design incorporates adjustable and reconfigurable winding arrangements where the spacing, orientation, and configuration of windings can be dynamically modified to match different PCB layout requirements. The structure allows for variable turns ratios and winding configurations that can be adapted during manufacturing or assembly to meet specific application needs.
2Quantity of substance
If transformer size is reduced to improve power density, then power density increases, but thermal management becomes more difficult
Solution Approach 1:
The transformer design utilizes three-dimensional winding arrangements and vertical stacking of winding layers to reduce the horizontal footprint while maintaining adequate thermal pathways. By transitioning from planar to spatial configurations, the transformer achieves higher power density without compromising thermal management, as heat can still dissipate through vertical and lateral pathways.
Solution Approach 2:
Thin insulating films are strategically placed between winding layers and around magnetic cores to enable compact packaging while maintaining thermal conductivity pathways. These thin films provide electrical insulation while allowing heat to transfer efficiently through the winding structure to heat sinks or ambient environments.
3Volume of moving object
If multiple transformers are integrated into a single device, then size and weight are reduced, but layout matching flexibility is lost
Solution Approach 1:
The integrated magnetic device is segmented into multiple independent transformer units, each with its own primary and secondary windings that can be independently configured. This segmentation allows the overall device to maintain a compact form factor while enabling flexible internal arrangement of individual transformer units to match different PCB layouts and electrical requirements.
Solution Approach 2:
The integrated magnetic core structure is designed with universal mounting interfaces and standardized winding configurations that can accommodate multiple different transformer arrangements within the same physical housing. This multi-functionality allows a single integrated device to serve various layout requirements without requiring custom-designed devices for each application.
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 effectively reduces transformer size, enhances power density, and improves conversion efficiency while allowing for flexible layout compatibility, thereby meeting diverse PCB requirements and improving thermal management.
Implementation Method 1
A transformer includes a core, a first secondary winding disposed around a first leg of the core, a second secondary winding disposed around a second leg of the core, and a third secondary winding disposed around a third leg of the core
Data Source
AI summary
A transformer winding includes a first metal sheet of a first sheet type and a second metal sheet of a second sheet type stacked with one on top of the other, and an insulating film disposed between the first and second metal sheets. Each sheet type includes a body in a ring shape with an opening on a lower portion of the ring shape, and a first terminal and a second terminal extending respectively downward from two ends of the opening. The first and second sheet types have same distance between the first and second terminals, and different distances from the first terminals to a centerline of the ring shape. The transformer winding may be made different by changing the distances from the first terminals to the centerline. A transformer including the transformer winding as the secondary winding is also provided.