Embedded Step-Up Toroidal Transformer Magnetic Flux Coupling
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Solution Overview
Problem
Existing embedded toroidal transformers are limited to 'step-down' and 'one-to-one' voltage responses, as the magnetic flux induced by the primary coil fails to effectively couple to the secondary coils due to difficulty in constraining the magnetic flux with metallic vias/traces, making it challenging to achieve a 'step-up' voltage response without increasing the toroidal footprint or requiring additional machining steps.
Innovation Solution
A step-up toroidal transformer design featuring a plurality of primary coil segments arranged in parallel around a toroidal core, with the secondary winding containing the magnetic field, allowing for a modified turns ratio that increases the induced voltage without expanding the toroidal footprint or requiring additional processing, by positioning the primary coil segments to constrain the magnetic field within the toroidal core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional embedded toroidal transformer designs are used, then the structure is simple and manufacturing is easy, but the magnetic flux fails to effectively couple to the secondary coils and step-up voltage response cannot be achieved
Solution Approach 1:
The primary winding is divided into multiple discrete primary coil segments positioned at different angular locations around the toroidal core. Each segment independently contributes to magnetic flux generation, and their combined effect creates a more effective coupled magnetic field that successfully links with the secondary coils, resolving the magnetic flux coupling inefficiency of traditional designs.
Solution Approach 2:
The patent positions primary coil segments at specific angular locations (e.g., 0°, 90°, 180°, 270°) around the toroidal core, creating non-uniform local magnetic field distributions that optimize flux coupling. This strategic local placement ensures that magnetic flux is generated at critical positions where it can most effectively couple with the secondary winding turns.
2Reliability
If the toroidal footprint is increased to accommodate better magnetic flux coupling, then magnetic flux coupling improves, but the device size increases
Solution Approach 1:
Instead of increasing the toroidal footprint area, the patent utilizes the angular dimension around the core by positioning multiple primary coil segments at different angular locations. This dimensional approach allows multiple windings to be packed within the same footprint, achieving improved magnetic flux coupling without expanding the device's planar dimensions.
3Reliability
If additional machining or post processing steps are added to achieve step-up voltage response, then step-up voltage response is achieved, but manufacturing complexity increases
Solution Approach 1:
The primary winding is segmented into multiple discrete coil segments that can be independently fabricated and then assembled around the toroidal core. This segmentation allows each segment to be manufactured using standard PCB or wire-winding techniques, avoiding the need for specialized machining or post-processing steps while achieving the desired step-up voltage response through the combined effect of multiple segments.
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 design effectively increases the voltage induced in the secondary winding by constraining the magnetic field, achieving a step-up transformer response without enlarging the toroidal footprint or adding machining steps, as demonstrated by the voltage response over time, where the stepped-up voltage is approximately four times the input voltage.
Implementation Method 1
the magnetic flux induced by a primary input coil fails to effectively couple to the secondary output coils
Implementation Method 2
containing the magnetic flux that is formed in the secondary
Data Source
AI summary
An embodied step-up toroidal transformer (100). The step-up toroidal transformer (100) includes a plurality of coil segments (102, 104, 106, 108). Each primary coil segment (102, 104, 106, 108) is separately comprised of a plurality of turns of an elongated conductor coiled around a toroidal shaped core (120). The plurality of primary coil segments (102, 104, 106, 108) are collectively disposed around a circumference defined by the toroidal shaped core (120). Each of the plurality of primary coil segments (102, 104, 106, 108) is electrically connected in parallel across a first primary input terminal (128) and a second primary input terminal (130). The step-up toroidal transformer (100) also includes a secondary winding (126) formed from a plurality of turns of a second elongated conductor coiled around the toroidal shaped core (136).