52 mm³ DC-DC Transformer with Embedded Core
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Solution Overview
Problem
Conventional DC-DC converter devices face limitations in miniaturization due to increased operational frequency leading to saturation and significant losses, particularly due to eddy current and hysteresis losses, and have limited operational frequency due to electrical reactance.
Innovation Solution
A miniaturized DC-DC converter device with a magnetic core embedded in an insulating substrate, featuring separate transformer windings and a control circuit with high-frequency switching signals, implemented using Silicon-on-Insulator or Silicon-on-Sapphire technology, to reduce losses and power consumption while maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the transformer's magnetic core is reduced to miniaturize the device, then the device size is reduced, but the core becomes saturated more quickly leading to operational losses in power transfer
Solution Approach 1:
The patent changes the operational frequency parameter from conventional low frequencies to high frequencies (1 MHz to 10 MHz or higher). This parameter change allows the use of smaller magnetic cores while maintaining efficient power transfer by reducing the time the core spends in saturation during each cycle, thereby resolving the contradiction between miniaturization and operational losses
Solution Approach 2:
The patent implements dynamic switching control using MOSFETs or IGBTs that can rapidly switch on and off at high frequencies. This dynamic control allows the transformer to operate in a regime where the core does not remain saturated, enabling smaller core sizes while maintaining efficiency through controlled transient operation
2Duration of action of moving object
If the operational frequency of the transformer is increased to reduce saturation time, then the saturation time is reduced, but significant losses occur due to eddy current losses and hysteresis losses
Solution Approach 1:
The patent optimizes the magnetic core material properties and geometry parameters to minimize eddy current and hysteresis losses at high frequencies. By carefully selecting materials with appropriate electrical resistivity and magnetic properties, and by optimizing core dimensions and winding configurations, the patent achieves low loss operation at frequencies of 1 MHz to 10 MHz or higher
Solution Approach 2:
The patent employs composite construction techniques including laminated magnetic cores or ferrite materials that combine electrical insulation layers with magnetic material layers. This composite structure reduces eddy current paths while maintaining magnetic flux density, thereby reducing losses at high operating frequencies
3Loss of energy
If the operational frequency is increased to improve power transfer efficiency, then the efficiency is improved, but the device is limited by electrical reactance of components
Solution Approach 1:
The patent changes the operational frequency parameter to high frequencies (1 MHz to 10 MHz or higher) where the reactance of parasitic capacitances and inductances becomes less significant relative to the switching impedance. This parameter change extends the usable frequency range while maintaining efficient power transfer
Solution Approach 2:
The patent implements dynamic switching control that adapts the duty cycle and switching timing to optimize performance across different load conditions and frequencies. This dynamic control compensates for frequency-dependent reactance effects, enabling broad operational frequency range adaptability
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 reduced power input requirements and minimized losses at high operating frequencies, allowing for a smaller magnetic core and overall device size, with the ability to operate efficiently at frequencies up to 10 MHz and power consumption of less than 1.5 W at full load.
Implementation Method 1
a magnetic core embedded in the insulating substrate, the magnetic core having non-zero dimensions of less than about 5.4 mm by about 5.4 mm by about 1.8 mm; separate primary and secondary transformer windings surrounding first and second regions of the magnetic core
Implementation Method 2
Reducing the size of the transformer's magnetic core, for example, results in the core becoming saturated more quickly, leading to operational losses in the transfer of electrical power from the primary winding to the second winding
Implementation Method 3
Increasing the operational frequency of the transformer leads to significant losses due to eddy current losses and hysteresis losses
Implementation Method 4
Increasing the operational frequency of the transformer leads to significant losses due to eddy current losses and hysteresis losses
Data Source
AI summary
A DC-DC converter includes an insulating substrate; a magnetic core embedded in the insulating substrate, the magnetic core having non-zero x, y and z dimensions of less than or equal to about 5.4 mm by about 5.4 mm by about 1.8 mm; separate primary and secondary transformer windings surrounding first and second regions of the magnetic core; and a control circuit including: an oscillator; a drive circuit coupled to the oscillator; and one or more switches coupled to the drive circuit; the drive circuit providing a switching signal to the one or more switches and energizing the one or more switches to provide a drive voltage to the primary transformer winding. The one or more switches are Field Effect Transistors implemented in a Silicon-on-Insulator configuration or as a Silicon-on-Sapphire configuration.