Matrix Transformer Core Recess for Cooling Pin Integration
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Solution Overview
Problem
Current matrix transformers integrated into printed circuit boards face limitations in cooling and electrical power capacity due to the constraints of magnetic core structures and winding configurations.
Innovation Solution
A matrix transformer design that includes a recess in one of the magnetic plates within the magnetic field-free zone allows for the integration of a cooling pin connected to a heat sink, enabling enhanced cooling and potentially higher electrical power handling without compromising the transformer's functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the magnetic core structure is made compact and integrated into the PCB, then the transformer achieves flat design and predictable heat dissipation, but the cooling capability and electrical power capacity are limited
Solution Approach 1:
The magnetic core is segmented into multiple magnetic legs arranged in a matrix pattern, allowing windings to be distributed across multiple legs. This segmentation creates magnetic field-free zones between the legs where cooling pins can be integrated without interfering with the magnetic flux paths, thereby enhancing cooling capability while maintaining the compact PCB-integrated design
Solution Approach 2:
Cooling pins are introduced as intermediary heat dissipation elements that extend through the magnetic core structure. These pins provide additional thermal pathways from the winding layers to the PCB, acting as mediators between the heat-generating windings and the heat-dissipating PCB, thereby improving cooling capability without compromising the compact integrated design
2Power
If the magnetic core structure is optimized for compact integration, then the transformer achieves predictable heat dissipation, but the electrical power capacity is limited
Solution Approach 1:
The magnetic core is divided into multiple magnetic legs arranged in a matrix, with windings distributed across multiple legs. This segmentation increases the effective winding area and allows for higher power handling capacity while maintaining a compact footprint. The matrix arrangement optimizes the use of magnetic material and enables better thermal management
Solution Approach 2:
The transformer design transitions from a planar winding arrangement to a three-dimensional matrix structure with multiple magnetic legs extending through the PCB. This dimensional transformation allows windings to be distributed in both horizontal and vertical directions, increasing the effective power capacity without proportionally increasing the device footprint or structural complexity
3Ease of manufacture
If windings are distributed over multiple magnetic legs to minimize conductor layers, then the transformer forms magnetic field-free zones, but the magnetic material utilization is reduced
Solution Approach 1:
The magnetic core structure serves multiple functions simultaneously: it provides magnetic flux paths through the organized magnetic legs, creates magnetic field-free zones for cooling pin integration, and supports distributed winding arrangements. This multi-functionality allows the same magnetic material structure to enable both ease of manufacture with minimized conductor layers and optimized magnetic material utilization
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 efficiently improves cooling and increases the electrical power capacity of the matrix transformer by utilizing the magnetic field-free zone for heat dissipation, while optimizing the use of magnetic material.
Implementation Method 1
magnetic fluxes therein partially cancel one another out, and magnetic losses caused by alternating magnetic fields are likewise reduced
Implementation Method 2
A recess is provided in one of the magnetic plates within the magnetic field-free zone of the one of the magnetic plates. The cooling pin is guided through the recess as far as a surface of the PCB
Data Source
AI summary
A matrix transformer includes a magnetic core structure and windings. The magnetic core structure includes magnetic legs and a pair of spaced-apart magnetic plates that are connected together by the magnetic legs. The windings are wrapped around the magnetic legs and have electric current flow directions which cause magnetic fluxes within the magnetic core structure that cancel out in a middle region of each magnetic plate thereby leaving the middle region of each magnetic plate to be a magnetic field-free zone. A first one of the magnetic plates has a recess extending through its middle region within its magnetic field-free zone. A cooling pin connected to a heat sink is insertable through the recess.