Modular Transformer-Rectifier Blocks With Vertical Substrate Integration
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Solution Overview
Problem
Conventional power converters face challenges in minimizing their physical footprint while maintaining high efficiency and thermal performance, particularly in applications with space constraints such as mobile devices and automotive systems.
Innovation Solution
A transformer-rectifier block design comprising a substrate with a transformer and rectifier circuit, where the transformer has primary and secondary windings wound in specific configurations, and the rectifier is mounted on the substrate, allowing for a compact and efficient power conversion module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional power converter designs are used, then performance and reliability are maintained, but physical footprint is large
Solution Approach 1:
The transformer and rectifier circuit are merged into a single integrated module, with the rectifier circuit mounted directly on the same substrate as the transformer. This integration reduces the overall physical footprint by eliminating separate mounting spaces and interconnections, while maintaining performance through optimized electrical connections and reduced parasitic effects.
Solution Approach 2:
The design transitions from a planar layout to a three-dimensional stacked configuration, with the transformer on one side of the substrate and the rectifier circuit on the opposite side. This vertical arrangement significantly reduces the horizontal footprint while preserving all necessary electrical connections and thermal pathways.
2Area of stationary object
If compact designs are implemented, then physical footprint is reduced, but thermal management becomes difficult
Solution Approach 1:
By stacking the transformer and rectifier circuit on opposite sides of the substrate vertically, the design reduces horizontal space occupation while creating dedicated thermal pathways through the substrate. This three-dimensional arrangement allows for effective heat dissipation without increasing the horizontal footprint.
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
The design reduces the overall footprint of power converters without compromising performance or reliability, enabling scalable and efficient power conversion for various applications.
Implementation Method 1
The transformer comprises a magnetic core, a first primary winding, a first secondary winding that is wound over the first primary winding
Data Source
AI summary
Disclosed are transformer-rectifier blocks for power converters. A transformer-rectifier block has a transformer and a rectifier circuit that are vertically integrated with a substrate. The transformer has a magnetic core, primary windings that have one or more turns, and secondary windings that are wound a single turn over corresponding primary windings. The transformer is mounted on one side of the substrate, and the rectifier circuit is mounted on an opposing side of the substrate.