Matrix Planar Transformer Core Volume Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional planar transformers face challenges in reducing core size and cost due to the complexity and expense of multiple windings, requiring expensive 'buried via' PCB processes or stacking multiple PCBs, and struggle with flux density design constraints, often necessitating large cores and increased core loss.
Innovation Solution
A matrix planar transformer design using a single core with a grid of round center posts and corner posts, featuring single-turn and multi-turn PCBs with interleaved windings, allowing for a multiple turn design with reduced core volume, minimized leakage, and balanced flux density, achieved through a two-layer PCB winding configuration and a flux shunt to separate windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If multiple turn windings are used in planar transformers, then core size can be reduced, but manufacturing complexity and cost increase due to requiring expensive 'buried via' PCB processes or stacking multiple PCBs
Solution Approach 1:
The patent segments the winding structure into multiple PCB layers, with each layer contributing a portion of the total turns. This allows multiple turn windings to be achieved through standard multi-layer PCB fabrication processes rather than complex buried via techniques or stacked PCB assemblies, reducing manufacturing complexity while maintaining reduced core size benefits
Solution Approach 2:
The patent transitions from planar single-layer windings to three-dimensional multi-layer PCB windings. By utilizing the vertical dimension of multi-layer PCB construction, the patent achieves multiple turn equivalents without requiring increased planar area or complex inter-PCB connections, thereby reducing core size while avoiding manufacturing complexity penalties
2Ease of manufacture
If one winding is limited to a single turn to ease design constraints, then manufacturing is simplified, but core size must be very large which increases cost and core loss
Solution Approach 1:
The patent segments the single-turn limitation across multiple PCB layers. Each layer can maintain simple single-turn or few-turn windings that are easy to manufacture, but the cumulative effect across layers achieves the required total turns, thereby avoiding the need for very large core size while preserving manufacturing simplicity
Solution Approach 2:
The patent merges multiple simple windings from different PCB layers into a single effective multi-turn winding. By combining the magnetic effects of simple windings from each layer, the patent achieves the functionality of complex multi-turn windings without the manufacturing complexity, avoiding the need for oversized cores
3Adaptability or versatility
If multiple separate PCBs are stacked and physically interconnected to achieve multiple windings, then winding flexibility increases, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple windings into a single multi-layer PCB structure rather than using multiple separate PCBs. This integration maintains winding flexibility through independent trace routing on each layer while eliminating the need for physical stacking and interconnection, thereby reducing device complexity and assembly complexity 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
This design reduces core volume, minimizes inter-winding leakage, and achieves high flux density with a low-profile transformer, balancing thermal and design considerations while reducing material and manufacturing costs.
Implementation Method 1
each core half comprises a matrix of round center posts arranged in a grid formation along with a plurality of corner posts disposed along the edges of the core halves to provide a magnetic flux return path
Implementation Method 2
matrix planar transformer assembly having a single core which comprises two core halves... a single-turn printed circuit board (PCB) having a single-turn PCB copper trace pattern... and a multi-turn PCB having a plurality of multi-turn PCB copper traces
Data Source
AI summary
A planar matrix transformer assembly. In one embodiment, the assembly comprises (a) a core comprising multiple center posts in a matrix pattern; and multiple edge posts along edges of the core for a magnetic flux return path; (b) a single-turn layer comprising a top winding on the top the layer to form a single turn around each center post; and a bottom winding electrically coupled to the top winding and on the bottom of the layer to form a single turn around each center post; and (c) a multi-turn layer comprising multiple top-side windings on top of the layer, wherein each top-side winding is a multi-turn winding around a different center post; and multiple bottom-side windings on the bottom of the multi-turn layer, wherein each bottom-side winding is (i) electrically coupled to a different top-side winding in a one-to-one correspondence, and (ii) a multi-turn winding around a different center post.