Magnetic Adhesive Layer for Planar Transformer Integration
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Solution Overview
Problem
High-quality isolation transformers are large and expensive, and existing smaller footprint designs face challenges in maintaining high isolation ratings and efficiency due to non-magnetic material gaps between magnetic pieces and laminate winding structures, which affect high-frequency operation and manufacturing costs.
Innovation Solution
The use of patterned conductive features on laminate sheets with an inkjet printed magnetic adhesive layer to attach magnetic core structures, eliminating non-magnetic gaps and enhancing magnetic coupling for improved performance and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-magnetic materials are dispensed to interconnect magnetic pieces and laminate winding structures, then electrical connection is achieved, but gaps of 20-25 um thickness are generated which adversely impact transformer efficiency and high-frequency operation
Solution Approach 1:
The patent changes the material parameter from non-magnetic to magnetic adhesive material, transforming the gap-filling material into a magnetically conductive substance that eliminates magnetic path discontinuities while maintaining electrical connection functionality
Solution Approach 2:
The patent uses a composite magnetic adhesive material that combines both adhesive properties for mechanical bonding and magnetic properties for magnetic flux continuity, creating a dual-functional interconnection layer that eliminates both mechanical gaps and magnetic gaps
2Ease of manufacture
If non-magnetic materials are used for interconnecting magnetic pieces, then assembly is simplified, but magnetic coupling between core pieces and windings is degraded
Solution Approach 1:
The patent changes the magnetic parameter of the adhesive material from non-magnetic to magnetic, enabling the material to conduct magnetic flux while maintaining the simplified dispensing assembly process
Solution Approach 2:
The magnetic adhesive material performs multiple functions simultaneously: mechanical bonding of components, filling of gaps, and providing magnetic flux path continuity, replacing the need for separate non-magnetic adhesive and magnetic sheet materials
3Reliability
If traditional wire wound transformers are used for high isolation rating, then isolation performance is achieved, but size and cost increase
Solution Approach 1:
The patent transitions from traditional three-dimensional wire-wound transformer geometry to a planar two-dimensional structure with stacked laminated cores and windings, achieving high isolation ratings through the planar configuration and magnetic coupling while significantly reducing overall volume
Solution Approach 2:
The patent divides the transformer into separate planar laminated core pieces and winding layers that can be independently manufactured and then assembled through stacking, enabling high isolation ratings between primary and secondary windings while reducing overall transformer size and cost
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 approach reduces manufacturing costs, eliminates non-magnetic material gaps, and enhances high-frequency performance by providing a compact, efficient, and cost-effective solution for planar passive component structures.
Implementation Method 1
an inkjet printed magnetic adhesive layer that attaches a core structure to the lamination structure
Data Source
AI summary
Apparatus to form a transformer, an inductor, a capacitor or other passive electronic component, with patterned conductive features in a lamination structure, and one or more ferrite sheets or other magnetic core structures attached to the lamination structure via one or more inkjet printed magnetic adhesive layers that join the magnetic core structure or structures to the lamination structure.