Embedded Ring-Core Transformer Layout for Low-Height Power Supplies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional transformers are difficult to reduce in height, limiting their application to large spaces and hindering the improvement of power density in power supply devices.
Innovation Solution
An embedded induction magnetic component with a magnetic core embedded in an insulation matrix, where windings penetrate and are wound around the core, utilizing a PCB molding process to minimize height and enhance electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional manufacturing processes are used for transformers, then the transformer can be manufactured with traditional structures, but the height of the transformer cannot be reduced to a small value
Solution Approach 1:
The magnetic core is embedded within the insulation matrix, and the winding penetrates and is wound around the embedded magnetic core. This nested arrangement allows the magnetic core to be positioned inside the insulation material rather than requiring separate mounting space, thereby reducing the overall height of the transformer while maintaining functional integrity.
Solution Approach 2:
The winding penetrates the insulation matrix in the vertical direction (from first end face to second end face) and then wraps around the magnetic core. This three-dimensional winding configuration through the insulation matrix eliminates the need for traditional side-mounted windings, reducing height occupation while achieving the required electromagnetic coupling.
2Quantity of substance
If the transformer height is reduced, then power density of the power supply device can be improved, but the transformer may not meet application requirements for electromagnetic performance
Solution Approach 1:
The patent changes the geometric parameters of the magnetic core (using a ring structure) and the winding configuration (penetrating and wrapping around the core) to achieve compact dimensions. These parameter modifications allow the transformer to maintain required electromagnetic performance while reducing height to improve power density.
Solution Approach 2:
The transformer uses a composite structure combining magnetic core material embedded in insulation matrix material, with windings integrated through both layers. This composite approach allows optimal electromagnetic performance from the magnetic core while the insulation matrix provides electrical isolation, enabling compact design without sacrificing reliability.
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 significantly reduces the transformer's height while maintaining functionality, improving power density and enabling flexible placement on power supply device boards.
Implementation Method 1
transformer is a key component in a power supply device for implementing a function of the power supply device, and may drive a switch transistor in the power supply device based on a principle of electromagnetic induction, to convert a direct current voltage into a high-frequency alternating current voltage
Data Source
AI summary
An induction magnetic component includes a magnetic core, an insulation matrix, and a winding, where the magnetic core is embedded in the insulation matrix, and the magnetic core is of a ring structure. In addition, the insulation matrix includes a first end face and a second end face that are disposed back to back, a part of the winding penetrates the insulation matrix in a direction from the first end face to the second end face, and the winding is wound around the magnetic core. In the induction magnetic component provided, the magnetic core is embedded in the insulation matrix, and the winding is wound around the magnetic core by penetrating the insulation matrix, so that a height of the induction magnetic component can be greatly reduced while meeting a use requirement for the induction magnetic component.