Laminated Isolation Transformer Package for Compact IC Integration
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Solution Overview
Problem
Transformers used for magnetic-coupling isolation barriers in electronic systems face manufacturing challenges, particularly for integrated circuit (IC) packages due to the inclusion of a magnetic core.
Innovation Solution
The development of an isolation transformer package with a laminated winding structure, which includes a substrate with conductive traces, a magnetic core made of soft ferromagnetic material, and a winding structure with insulator material, configured to form primary and secondary coils around the magnetic core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional magnetic core structures are used in isolation transformers, then magnetic coupling and galvanic isolation are achieved, but manufacturing complexity and cost increase for IC packages
Solution Approach 1:
The patent combines the magnetic core, primary winding, and secondary winding into a single integrated transformer component that can be directly mounted on the PCB. This merging eliminates the need for separate magnetic core assemblies and complex winding processes, thereby achieving galvanic isolation while simplifying manufacturing for IC packages.
Solution Approach 2:
The transformer component serves multiple functions: providing magnetic coupling for signal transmission, achieving galvanic isolation between circuits, and acting as an integrated package that can be directly mounted on standard PCBs. This multi-functionality reduces the number of separate components needed and simplifies the overall manufacturing process.
2Reliability
If traditional magnetic core structures are used in isolation transformers, then magnetic coupling is achieved, but package size increases
Solution Approach 1:
The patent implements a nested structure where the primary and secondary windings are arranged concentrically around the magnetic core. This nesting allows the windings to be closely coupled with minimal spacing, maximizing magnetic coupling efficiency while minimizing the overall volume of the transformer package.
Solution Approach 2:
The transformer is designed with a planar footprint that can be mounted on the PCB surface, utilizing the two-dimensional plane rather than requiring significant three-dimensional space. This dimensional approach allows the magnetic core and windings to be arranged in a compact configuration that achieves effective magnetic coupling without increasing package volume.
3Reliability
If traditional magnetic core structures are used in isolation transformers, then galvanic isolation is achieved, but cost increases
Solution Approach 1:
The patent segments the transformer into discrete, standardized components with defined magnetic core geometries and winding configurations. This segmentation allows for mass production using automated winding machines and standard manufacturing processes, thereby reducing the cost of achieving galvanic isolation compared to custom-built traditional transformers.
Solution Approach 2:
The patent optimizes parameters such as magnetic core material composition, winding wire gauge, and turn ratios to achieve the required galvanic isolation performance at lower cost. By carefully selecting and adjusting these parameters, the design maintains reliable isolation while reducing material costs and manufacturing complexity.
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 solution enables the creation of smaller, cost-effective, and scalable IC packages with voltage-isolated IC die and transformers, addressing the manufacturing issues associated with traditional magnetic-coupling isolation barriers.
Implementation Method 1
Magnetic coupling typically relies on use of a transformer to magnetically couple circuits on the different sides of the transformer
Implementation Method 2
the magnetic core includes a soft ferromagnetic material
Data Source
AI summary
Aspects of the present disclosure include systems, structures, circuits, and methods providing laminated winding structures with coil portions for transformers. Transformer packages can include substrates with winding portions that connect to laminated winding structures to form complete transformer coils configured about a transformer core. The laminated winding structures can include spaces to receive a transformer core when mounted on a substrate. The packages and modules may include various types of circuits; in some examples, chip packages or modules may include a galvanically isolated gate driver or other high voltage circuit.