Modular Planar Transformer Windings for Shorter Production Cycles
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Solution Overview
Problem
Conventional planar transformers have complex manufacturing processes, long production cycles, low fault tolerance, and limited flexibility due to their multi-layered circuit board design, making them costly and time-consuming to produce and adjust.
Innovation Solution
A planar transformer design featuring individual printed circuit boards and winding modules with a magnetic core assembly, where the winding modules include a second winding covered by a plastic molding layer, reducing the number of winding layers on the circuit board and allowing for separate assembly and adjustment of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If all windings are formed on a single multi-layered circuit board, then the planar transformer achieves compact integration, but the fabricating process becomes more complicated and the production cycle becomes longer
Solution Approach 1:
The patent divides the transformer into separate modules: a circuit board module containing control windings and a winding module containing power windings. This segmentation allows each module to be manufactured independently and then assembled together, reducing the production cycle while maintaining compact integration through modular assembly rather than requiring all windings on a single multi-layered board
2Quantity of substance
If the number of layers on the circuit board increases, then more windings can be accommodated, but the fabricating cost increases and fault tolerance rate decreases
Solution Approach 1:
The patent separates windings into two modules: control windings on the circuit board and power windings in the winding module. This avoids the need for a high-layer-count single board, reducing fabrication complexity and cost while accommodating all necessary windings through modular architecture
Solution Approach 2:
The patent introduces a winding module as an intermediary component that houses power windings separately from the circuit board. This intermediary module allows the system to accommodate multiple windings without increasing circuit board layer count, thereby reducing fabrication cost and improving fault tolerance
3Adaptability or versatility
If the circuit board design needs to be adjusted for changing interlayer capacitance or turn number, then the transformer configuration can be optimized, but the production cycle becomes longer due to re-design requirements
Solution Approach 1:
The patent separates adjustable parameters into different modules: interlayer capacitance can be adjusted in the circuit board module while turn number can be adjusted in the winding module. This segmentation allows independent optimization of each module without requiring complete re-design, reducing the production cycle while maintaining design flexibility
Solution Approach 2:
The patent creates a dynamically adjustable system where the winding module can be independently modified to change turn numbers and the circuit board can be adjusted for interlayer capacitance. These modular adjustments enable optimization without full re-design, maintaining adaptability while reducing production cycle through localized modifications rather than complete board re-design
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 shortens production cycles, increases fault tolerance, reduces fabrication costs, and enhances flexibility in adjusting the transformer's configuration.
Implementation Method 1
The magnetic core assembly includes a first magnetic core and a second magnetic core
Implementation Method 2
The printed circuit board includes a first winding. The winding module includes a second winding
Implementation Method 3
The magnetic conductive sheet is disposed between the first magnetic core and the second magnetic core to form a leakage inductance required by the planar transformer
Implementation Method 4
The at least one winding module is disposed between the first magnetic core and the second magnetic core. The winding module includes a second winding and a plastic molding layer. At least a portion of the second winding is covered by the plastic molding layer
Data Source
AI summary
A planar transformer includes a magnetic core assembly, at least one printed circuit board, a magnetic conductive sheet and at least one winding module. The magnetic core assembly includes a first magnetic core and a second magnetic core. The printed circuit board is disposed between the first magnetic core and the second magnetic core. The printed circuit board includes a first winding. The magnetic conductive sheet is disposed between the first magnetic core and the second magnetic core to form a leakage inductance required by the planar transformer. The at least one winding module is disposed between the first magnetic core and the second magnetic core. The winding module includes a second winding and a plastic molding layer. At least a portion of the second winding is covered by the plastic molding layer. The at least one printed circuit board and the at least one winding module are individual components.