Embedded Solenoid Transformer for VHF Power Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current power converters, especially those operating at radio frequencies, face challenges in achieving small, efficient, and cost-effective transformer designs due to high switching losses and the large size of inductive components.
Innovation Solution
A transformer design featuring a printed circuit board with two horizontal conductive layers separated by an isolating layer, where the first and second solenoids are embedded, forming a primary and secondary winding respectively, with each full turn having horizontal top and bottom portions and vertical side portions formed by vias, enabling efficient coupling and reducing component size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional inductive components are used in power converters, then power conversion function is achieved, but component size and weight become large
Solution Approach 1:
The patent transitions from traditional three-dimensional wound coil transformers to a planar two-dimensional PCB-based solenoid structure. The primary and secondary windings are formed as flat solenoids on opposite sides of a PCB, with vertical vias providing the third-dimensional connection. This dimensional change dramatically reduces the volume and weight of the transformer while maintaining the necessary magnetic coupling for power conversion.
Solution Approach 2:
The patent replaces the mechanical winding process with automated PCB fabrication techniques. Instead of manually or mechanically winding copper wire around a core, the transformer windings are created through standard PCB processes: copper traces on the PCB surface form the horizontal portions of the solenoids, and plated through-holes (vias) form the vertical connections. This substitution enables precise, repeatable, and compact transformer structures.
2Productivity
If switching frequency is increased to reduce passive component size, then power density increases, but switching losses increase
Solution Approach 1:
The patent changes the physical parameters of the inductive components by using planar solenoid structures with optimized geometry. The solenoids are formed with specific trace widths, via diameters, and winding patterns that optimize the inductance values for high-frequency operation. This parameter optimization allows the transformer to maintain low losses at elevated switching frequencies, enabling higher power density without proportionally increasing switching losses.
3Volume of moving object
If transformer size is reduced for compact power converters, then power supply size decreases, but manufacturing complexity increases
Solution Approach 1:
The patent makes the PCB serve multiple functions simultaneously: it provides mechanical support for the transformer, electrical insulation between primary and secondary windings, structural framework for the solenoid geometry, and electrical connectivity through vias. This multi-functionality eliminates the need for separate transformer forms, insulation materials, and mounting structures, thereby simplifying manufacturing despite the compact design.
Solution Approach 2:
The patent merges the transformer structure with the PCB structure. The transformer windings are not separate components but are integrated directly into the PCB layers. The copper traces and vias that form the solenoids are created using the same PCB fabrication processes that create other circuit elements, consolidating multiple manufacturing steps into a single integrated structure.
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
This design results in a compact, low-profile, low-weight, and cost-effective power converter with high reproducibility, suitable for applications like LED lighting and mobile devices, while minimizing losses and production costs.
Implementation Method 1
a first embedded solenoid forming a primary winding of the transformer and a second embedded solenoid being arranged parallel to the first solenoid and forming a secondary winding of the transformer
Data Source
AI summary
A resonant power converter for operation in the radio frequency range, preferably in the VHF, comprises at least one PCB-embedded transformer. The transformer is configured for radio frequency operation and comprises a printed circuit board defining a horizontal plane, the printed circuit board comprising at least two horizontal conductive layers separated by an isolating layer, a first embedded solenoid forming a primary winding of the transformer and a second embedded solenoid being arranged parallel to the first solenoid and forming a secondary winding of the transformer, wherein the first and second embedded solenoids are formed in the conductive layers of the printed circuit board, wherein each full turn of an embedded solenoid has a horizontal top portion formed in an upper conductive layer, a horizontal bottom portion formed in a lower conductive layer, and two vertical side portions formed by vias extending between the upper and the lower conducting layers.