Embedded Transformer Windings for Isolation and Coupling
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Solution Overview
Problem
Embedded magnetic component transformers face challenges in reducing coupling and improving isolation while maintaining a compact size, as smaller transformers lead to increased coupling between windings and reduced electrical isolation, which is unsafe for high-voltage applications.
Innovation Solution
The design includes a magnetic core embedded in an insulating substrate with primary, secondary, and auxiliary windings, where the auxiliary winding is positioned farther from the magnetic core periphery than the primary and secondary windings, and a conductive element is used to shield electric fields, enhancing electrical isolation and reducing coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the transformer size is reduced to achieve a more compact device, then the footprint and overall size are reduced, but the coupling between windings increases and electrical isolation decreases
Solution Approach 1:
The patent positions windings on opposite sides of the magnetic core (primary winding on first side, secondary winding on second side), utilizing the third dimension through the core to achieve spatial separation. This dimensional arrangement reduces coupling and improves isolation without increasing the transformer's planar footprint, thus resolving the contradiction between compact size and electrical isolation.
2Area of stationary object
If the gap between adjacent turns is reduced to achieve a more compact transformer, then the footprint is reduced, but the magnetic field coupling between windings becomes stronger
Solution Approach 1:
The patent segments the transformer structure by placing primary and secondary windings on opposite sides of the magnetic core, creating physical separation between the windings. This segmentation reduces the magnetic field coupling between adjacent turns while maintaining a compact footprint, as the windings are divided into separate spatial zones rather than being closely wound together.
3Volume of moving object
If the distance between electrically isolated windings is reduced to achieve a smaller transformer, then the compactness is improved, but the safety against electrical arcing decreases
Solution Approach 1:
The magnetic core acts as an intermediary barrier between the primary and secondary windings. By positioning windings on opposite sides of the core, the core material provides both magnetic coupling functionality and electrical isolation, preventing direct arcing between windings while maintaining compact dimensions. The core serves as a mediating structure that enables close proximity without compromising safety.
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 achieves improved electrical isolation and reduced coupling between windings, allowing for safer operation at higher voltages while maintaining a compact transformer size, suitable for power converter applications.
Implementation Method 1
a magnetic core housed in the cavity; a primary winding extending through the insulating substrate and around the first side of the magnetic core; a secondary winding extending through the insulating substrate and around the second side of the magnetic core
Data Source
AI summary
A transformer device includes primary, secondary, and auxiliary windings, located in an insulating substrate by conductive vias joined together by conductive traces. Positions of the conductive vias are arranged so as to optimize the isolation properties of the transformer, and to improve the coupling of the transformer by increasing the leakage inductance and reducing the distributed capacitance. The transformer device is compact and is weakly coupled. The weak coupling between the windings reduces the likelihood of the transformer malfunctioning, particularly when used in a self-resonant converter circuit.