Laminated Transformer Layout for Thin Profile and Higher Coupling
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Solution Overview
Problem
Traditional ferrite transformers are bulky due to their thickness and have high thermal resistance, and laminated transformers with low coupling coefficients struggle to achieve desired characteristics for miniaturization and performance.
Innovation Solution
A laminated transformer design incorporating multiple magnetic and non-magnetic layers, where non-magnetic layers are strategically placed between coil layers to increase the coupling coefficient, and a manufacturing method involving casting, screen printing, and lamination to reduce thickness and enhance thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional ferrite lamination process is used, then small volume ultra-thin inductance is achieved, but transformer thickness remains large and thermal resistance is high
Solution Approach 1:
The transformer core is divided into multiple thin magnetic layers (e.g., 5-10 layers) with non-magnetic layers interspersed between them. Each magnetic layer has a thickness of 0.05-0.2mm, creating a segmented structure that reduces overall transformer thickness while improving thermal performance through the distributed layering.
Solution Approach 2:
Non-magnetic layers (such as insulation layers or air gaps) are introduced as intermediary elements between the magnetic layers. These non-magnetic layers have thermal conductivity different from the magnetic material, creating thermal pathways that reduce overall thermal resistance while maintaining electrical insulation.
2Length of stationary object
If laminated structure is used to reduce thickness, then transformer thickness is reduced, but coupling coefficient between coils decreases
Solution Approach 1:
The non-magnetic layers are strategically positioned at specific locations within the laminated structure, particularly between coil layers, rather than uniformly distributed. This localized placement optimizes the coupling coefficient in critical regions while maintaining overall thickness reduction.
Solution Approach 2:
The transformer employs a composite structure combining magnetic layers (for magnetic flux conduction) with non-magnetic layers (for insulation and thermal management). This composite material approach allows optimization of both magnetic coupling and thermal properties simultaneously.
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 design achieves a reduction in transformer thickness, improves thermal performance, and enhances the coupling coefficient between primary and secondary coils, leading to a more efficient and compact transformer.
Implementation Method 1
a first of the plurality of non-magnetic layers is disposed between an adjacent pair of the coil layers in order to increase a coupling coefficient between the primary and secondary coils
Data Source
AI summary
A laminated transformer can include: a plurality of magnetic layers; a plurality of coil layers including a primary coil having a first type of coil layer, and a secondary coil having a second type of coil layer, where each coil layer is laminated between a pair of the plurality of magnetic layers; and a plurality of non-magnetic layers, where a first of the plurality of non-magnetic layers is disposed between an adjacent pair of the coil layers in order to increase a coupling coefficient between the primary and secondary coils.