Embedded Transformer Module with Spiral Windings
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Solution Overview
Problem
Existing embedded magnetic component devices face challenges in miniaturization and cost reduction due to the size and weight of magnetic components, and issues with air bubbles in epoxy gel and required isolation distances affecting transformer coupling and reliability.
Innovation Solution
An embedded transformer module with horizontally wound spiral primary and secondary windings around a magnetic core, separated by insulating layers, and a method of manufacturing that includes a substrate with a magnetic core, windings, and additional layers for improved isolation and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air bubbles are allowed to form in the epoxy gel during solidification, then the manufacturing process is simple, but the device reliability deteriorates due to expansion during reflow soldering
Solution Approach 1:
The patent removes the harmful air bubbles from the epoxy gel before solidification by applying vacuum treatment. This extracts the harmful factor (air bubbles) that would otherwise expand during reflow soldering and cause device failure, while maintaining the simple embedded manufacturing process
Solution Approach 2:
The patent applies preliminary anti-action by removing air bubbles through vacuum treatment before the epoxy gel solidifies and before reflow soldering occurs. This preliminary removal prevents the harmful expansion effect from occurring during subsequent heating processes
2Reliability
If a large isolation distance is provided between primary and secondary windings, then insulation requirements are met, but the transformer coupling deteriorates
Solution Approach 1:
The patent introduces an intermediary magnetic shielding layer between the primary and secondary windings. This shielding layer acts as a mediator that provides the necessary electrical isolation and magnetic field management, allowing reduced physical spacing while maintaining both insulation performance and magnetic coupling efficiency
Solution Approach 2:
The patent transitions from relying solely on increased physical distance (one-dimensional solution) to using a magnetic shielding layer (introducing a new dimensional approach). The shielding layer provides isolation through material properties rather than just spatial separation, enabling compact transformer design with good coupling
3Power
If magnetic components are made larger to improve performance, then coupling and power handling are enhanced, but miniaturization and cost reduction become difficult
Solution Approach 1:
The patent embeds the magnetic core and windings within a cavity in the PCB substrate, creating a nested structure where the transformer components are housed within the board itself. This nesting approach reduces overall device volume and eliminates the need for separate discrete magnetic components, achieving miniaturization while maintaining performance
Solution Approach 2:
The patent merges the transformer magnetic core and windings with the PCB substrate by embedding them directly in the board structure. This consolidation combines multiple components (substrate, magnetic core, windings, insulation) into a single integrated assembly, reducing total volume and component count while maintaining electrical and magnetic performance
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 reduces the isolation distance between windings, enhances coupling, and improves reliability by using insulating layers and thermal pillars, allowing for more compact and efficient transformer designs while meeting insulation requirements.
Implementation Method 1
an embedded transformer module with horizontally wound spiral primary and secondary windings around a magnetic core
Data Source
AI summary
An embedded transformer module device includes an insulating substrate including a first side and a second side opposite to the first side and including a first cavity, a magnetic core in the first cavity, a primary winding wound horizontally around the magnetic core and having a spiral shape with more than one turn, and a secondary winding wound horizontally around the magnetic core, spaced away from the primary winding, and having a spiral shape with more than one turn.