Embedded Transformer Interleaved Windings Thermal Balance
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Solution Overview
Problem
Embedded transformers face challenges in maintaining electrical performance due to increased heating and reduced electrical isolation caused by compact designs, which can lead to hot-spots and performance degradation, especially when space constraints prevent the use of heat sinks or larger circuit boards.
Innovation Solution
The design incorporates interleaved electrical windings around a magnetic core within an insulating substrate, with transistors energizing alternating winding portions to distribute heat evenly and maintain electrical isolation, using conductive traces and connectors to define turns and provide equal thermal stress on transistors, and potentially including auxiliary windings for feedback and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the transformer size is reduced to save space, then the device becomes more compact and space-efficient, but the winding turns are placed closer together causing increased heating and hot-spots
Solution Approach 1:
The primary winding is divided into two separate sections (first section and second section) that are positioned on opposite sides of the magnetic core. This segmentation distributes the heat generation across different spatial locations rather than concentrating it in one area, thereby reducing hot-spot formation while maintaining compact dimensions.
Solution Approach 2:
The patent utilizes the three-dimensional space around the magnetic core by positioning windings on opposite sides and using conductive connectors that pass through the substrate. This dimensional arrangement allows for better heat distribution and electrical connectivity without increasing the overall footprint of the transformer.
2Volume of moving object
If the gap between separate windings is reduced to save space, then the device becomes more compact, but electrical isolation between windings is compromised increasing the risk of electrical arcing
Solution Approach 1:
An insulating substrate is introduced as an intermediary material between the primary and secondary windings. This substrate provides electrical isolation and prevents arcing while allowing the windings to be positioned close together for compact design. The substrate acts as a mediator that enables both compactness and electrical safety.
3Temperature
If heat sinks or larger circuit boards are used to mitigate heating, then the thermal management improves, but the device size increases which is impossible due to tight space restrictions
Solution Approach 1:
The conductive connectors serve dual functions: they provide electrical connectivity between the windings and simultaneously act as thermal pathways to conduct heat away from the winding areas. By merging these two functions into a single component, the patent achieves heat dissipation without adding separate heat sink structures that would increase device size.
4Reliability
If electrical path length differences between transformer coil and controlling components are reduced, then electrical performance improves, but the design complexity increases
Solution Approach 1:
The patent intentionally positions the primary and secondary windings asymmetrically on opposite sides of the magnetic core, with each winding having its own dedicated transistors. This asymmetric design allows for optimized electrical path lengths for each winding-transistor pair, improving electrical performance while maintaining manageable complexity through clear functional separation.
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 configuration enhances electrical performance by evenly distributing heat and maintaining isolation, reducing thermal stress and asymmetries in the transformer's operation, leading to more balanced and efficient energy conversion.
Implementation Method 1
a magnetic core housed in the cavity including a first section and a second section; a first electrical winding, passing through the insulating substrate and disposed around the first section of the magnetic core; a second electrical winding, passing through the insulating substrate and disposed around the second section of the magnetic core
Implementation Method 2
conductive connectors passing through the insulating substrate adjacent the inner periphery of the magnetic core, the inner conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive traces
Data Source
AI summary
An embedded magnetic component transformer includes first, second, and auxiliary electrical windings in an insulating substrate including conductive vias joined together by conductive traces. The first electrical windings are divided by a tap terminal into first and second winding portions, which are interleaved with one another and energized by separate transistors. Heat generated by the first and second winding portions is transferred more equally to the separate transistors. Equal or substantially equal path lengths between each of the transistors and the first electrical windings improve flux balance allowing the transistors to conduct for equal or substantially equal times during a switching cycle. Thus, the switching cycle of the embedded transformer is more symmetric with respect to each of the transistors and winding portions, improving the electrical characteristics of the transformer.