High-Frequency Transformer With Segmented Multilayer Coils
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Solution Overview
Problem
Conventional high-frequency transformers face challenges in miniaturization due to limitations in materials with high saturation magnetic flux density or magnetic permeability, making it difficult to achieve a high coupling coefficient and low loss in laminated types.
Innovation Solution
A high-frequency transformer design using a sheet multilayer process with odd- and even-numbered coil conductor patterns embedded in a laminated body, where the directions of magnetic fields in different axes are opposite, allowing for high coupling without the need for materials with high saturation magnetic flux density or magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a laminated high-frequency transformer is manufactured using a sheet multilayer process with conventional materials, then it is easy to manufacture and miniaturization is possible, but the coupling coefficient is low and loss is high due to limitations in materials with high saturation magnetic flux density or magnetic permeability
Solution Approach 1:
The coil structure is segmented into odd-numbered and even-numbered coil conductor patterns that are arranged in an interleaved manner. This segmentation allows each pattern to contribute to the magnetic coupling independently, achieving high coupling coefficient without requiring specialized magnetic materials that are difficult to manufacture with sheet multilayer processes
Solution Approach 2:
The patent transitions from conventional single-plane coil winding to a multi-layer three-dimensional arrangement where odd and even coil patterns are distributed across multiple laminated layers. This dimensional expansion enables magnetic flux to couple through multiple paths simultaneously, achieving high coupling coefficient while maintaining compatibility with standard sheet multilayer manufacturing processes
2Ease of manufacture
If a laminated high-frequency transformer is manufactured using a sheet multilayer process with conventional materials, then it is easy to manufacture and miniaturization is possible, but loss is high due to limitations in materials with high saturation magnetic flux density or magnetic permeability
Solution Approach 1:
The coil structure is segmented into odd-numbered and even-numbered coil conductor patterns that are arranged in an interleaved manner. This segmentation allows each pattern to contribute to the magnetic coupling independently, achieving high coupling coefficient without requiring specialized magnetic materials that are difficult to manufacture with sheet multilayer processes
Solution Approach 2:
The patent transitions from conventional single-plane coil winding to a multi-layer three-dimensional arrangement where odd and even coil patterns are distributed across multiple laminated layers. This dimensional expansion enables magnetic flux to couple through multiple paths simultaneously, achieving high coupling coefficient while maintaining compatibility with standard sheet multilayer manufacturing processes
3Reliability
If materials with high saturation magnetic flux density or magnetic permeability are used, then a high coupling coefficient can be achieved, but it is difficult to manufacture using sheet multilayer process and miniaturization is limited
Solution Approach 1:
The coil structure is segmented into odd-numbered and even-numbered coil conductor patterns that are arranged in an interleaved manner. This segmentation allows each pattern to contribute to the magnetic coupling independently, achieving high coupling coefficient without requiring specialized magnetic materials that are difficult to manufacture with sheet multilayer processes
Solution Approach 2:
The patent transitions from conventional single-plane coil winding to a multi-layer three-dimensional arrangement where odd and even coil patterns are distributed across multiple laminated layers. This dimensional expansion enables magnetic flux to couple through multiple paths simultaneously, achieving high coupling coefficient while maintaining compatibility with standard sheet multilayer manufacturing processes
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 results in a high-frequency transformer with a small leakage magnetic field and high coupling coefficient, facilitating miniaturization while maintaining stable frequency characteristics across a wide frequency band.
Implementation Method 1
the odd-numbered coil conductor pattern of the primary coil, the even-numbered coil conductor pattern of the primary coil, the odd-numbered coil conductor pattern of the secondary coil, and the even-numbered coil conductor pattern of the secondary coil are wound such that when currents flow through the primary coil and the secondary coil, directions of a magnetic field occurring in the first axis and a magnetic field occurring in the second axis are opposite to each other
Data Source
AI summary
In a high frequency transformer, when a current flows between input-output ports, a magnetic flux produced by first and third coil conductor patterns of a primary coil is interlinked with a second coil conductor pattern of a secondary coil. A magnetic flux produced by the second coil conductor pattern of the primary coil is interlinked with the first and third coil conductor patterns of the secondary coil. The coil conductor patterns are wound so that when a current flows through a transformer, the directions of magnetic fields occurring within the first and third coil conductor patterns of the primary coil and the second coil conductor pattern of the secondary coil are the same and the directions of magnetic fields occurring within the first and third coil conductor patterns of the secondary coil and the second coil conductor pattern of the primary coil are the same.