Foil Winding Transformer Module for Even Current Distribution
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Solution Overview
Problem
The existing transformer technologies for low-voltage and high-current applications face issues with uneven current distribution due to inconsistent equivalent diameters and impedances in multi-layer PCB winding structures, leading to increased winding losses and inefficiencies.
Innovation Solution
A transformer module with a foil winding structure, where multiple wiring layers are sequentially disposed on a magnetic core with insulating layers in between, and connectors passing through these layers for even current distribution and reduced losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-layer PCB winding structure is used, then power density is improved, but current distribution becomes uneven due to inconsistent equivalent diameters and impedances
Solution Approach 1:
The winding structure is divided into multiple independent PCB layers, with each layer forming a complete winding. Connectors are distributed across different layers to connect corresponding winding ends, enabling even current distribution while maintaining high power density through vertical stacking of winding layers
Solution Approach 2:
The invention transitions from planar winding arrangement to three-dimensional multi-layer structure. Windings are arranged vertically across multiple PCB layers, with connectors passing through the magnetic core to establish electrical connections between corresponding layers, achieving both high power density and uniform current distribution
2Power
If multi-layer PCB winding structure is used, then power density is improved, but winding losses increase due to uneven current distribution
Solution Approach 1:
The winding structure is divided into multiple independent PCB layers, with each layer forming a complete winding. Connectors are distributed across different layers to connect corresponding winding ends, enabling even current distribution while maintaining high power density through vertical stacking of winding layers
Solution Approach 2:
The invention transitions from planar winding arrangement to three-dimensional multi-layer structure. Windings are arranged vertically across multiple PCB layers, with connectors passing through the magnetic core to establish electrical connections between corresponding layers, achieving both high power density and uniform current distribution
3Ease of manufacture
If conventional PCB winding with centralized connectors is used, then manufacturing is simplified, but current distribution becomes uneven at connector joints
Solution Approach 1:
The winding structure is divided into multiple independent PCB layers, with each layer forming a complete winding. Connectors are distributed across different layers to connect corresponding winding ends, enabling even current distribution while maintaining high power density through vertical stacking of winding layers
Solution Approach 2:
The invention transitions from planar winding arrangement to three-dimensional multi-layer structure. Windings are arranged vertically across multiple PCB layers, with connectors passing through the magnetic core to establish electrical connections between corresponding layers, achieving both high power density and uniform current distribution
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 foil winding structure ensures even current distribution across the transformer module, reducing winding losses and improving power density and efficiency.
Implementation Method 1
different portions of the winding have almost the same distance to the magnetic core, that is, the equivalent diameters of different portions e.g. R1B and R2B are almost the same. Thus equivalent impedance of different portions is almost the same. So the current distribution of the winding in a foil structure is almost even
Implementation Method 2
a magnetic core, a first wiring layer, a first insulating layer and a second wiring layer being sequentially disposed on the magnetic core from outside to inside
Data Source
AI summary
The present disclosure provides a manufacturing process of a metal winding, where the manufacturing process includes: cutting a first metal copper foil to form a connector and a pin; performing insulation processing on a surface of at least one of the first metal copper foil and a second metal copper foil; bending the first metal copper foil to form a first metal winding to cover on a magnetic core; and covering the second metal copper foil at least partially on a surface of the first metal copper foil to form a second metal winding, and a pin of the first metal winding passes through the second metal winding.