Hybrid PCB Transformer Layout for High-Voltage Isolation
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Solution Overview
Problem
Conventional transformers for power supplies with high input voltage and low output voltage require large size, high manufacturing time, and increased costs due to complex dielectric layer formation, which hinders efficiency and time-to-market.
Innovation Solution
A hybrid transformer design featuring surface-mounted wire coils on opposing sides of a printed circuit board (PCB) with a core extending through the PCB, and a header for electrical coupling, allowing for improved power density, reduced material usage, and accelerated manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transformers with thick dielectric layers are used for high voltage isolation, then safety requirements are met, but manufacturing time increases to approximately six weeks and complexity increases
Solution Approach 1:
The transformer is divided into separate modules: wire-wound coils are manufactured independently and then surface-mounted onto the PCB. This segmentation allows parallel manufacturing of coils and circuit boards, eliminating the sequential process of growing thick dielectric layers, thereby reducing manufacturing time while maintaining isolation safety through proper clearances and creepage distances in the segmented design.
Solution Approach 2:
The design transitions from planar PCB-integrated coils to three-dimensional wire-wound coils surface-mounted on the PCB. This dimensional change allows for more effective use of isolation space through vertical positioning and optimized winding structures, achieving required voltage isolation without requiring thick dielectric layers, thus reducing manufacturing complexity and time.
2Device complexity
If planar transformers with multilayer PCBs are used, then both primary and secondary windings can be integrated, but manufacturing becomes time-consuming and labor intensive
Solution Approach 1:
The transformer construction is segmented into independently manufacturable components: wire-wound coils are prepared separately using automated winding machines, and the PCB is manufactured separately using standard PCB fabrication processes. These segments are then assembled together through surface-mount technology, which is highly automated and reduces labor intensity compared to growing thick dielectric layers.
Solution Approach 2:
The mechanical process of growing thick dielectric layers through PCB lamination is replaced with an electrical assembly process where pre-wound coils are surface-mounted onto the PCB. This substitution leverages automated SMT equipment instead of time-consuming thermal lamination processes, significantly reducing manufacturing time and labor requirements while maintaining the integrated winding functionality.
3Power
If high turns ratio transformers are used for high input voltage to low output voltage conversion, then voltage transformation is achieved, but component size and power density are reduced
Solution Approach 1:
The design changes the operating parameters by utilizing high-frequency switching (typically 20-100 kHz or higher) instead of conventional 50/60 Hz operation. This frequency increase allows for significantly smaller magnetic core sizes and fewer turns in the windings while achieving the same voltage transformation ratio, thereby reducing overall transformer volume and improving power density.
Solution Approach 2:
The transformer employs composite construction combining wire-wound coils with PCB-mounted components. The wire-wound coils provide efficient magnetic coupling and can be optimized for high-frequency operation, while the PCB provides structural support and electrical connections. This composite approach enables compact design with improved power density compared to traditional all-PCB or all-wire-wound designs.
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 hybrid transformer achieves efficient power conversion with reduced power dissipation and improved efficiency across a range of input voltages and output currents, compared to conventional transformers, while also decreasing manufacturing time and costs.
Implementation Method 1
A hybrid transformer may include first and second wire coils arranged on opposing surfaces of a printed circuit board (PCB), a core extending through the PCB, wherein the first and second coils are each wound around the core
Data Source
AI summary
Illustrative embodiments of hybrid transformers, power supplies, and methods relating to the same are disclosed. In at least one embodiment, a hybrid transformer includes first and second wire coils arranged on opposing surfaces of a printed circuit board (PCB), a core extending through the PCB, wherein the first and second coils are each wound around the core, and at least one header electrically coupling one of the first and second wire coils to the PCB.