Multi-Chamber Transformer Mounting for Compact PCB Cooling
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Solution Overview
Problem
Existing multi-chamber transformers for solid-state lighting sources face challenges in compactness, heat dissipation, voltage overload capacity, and cost efficiency, particularly when mounted on substrates like PCBs, due to increased dimensions and complex winding configurations that hinder automated production and electrical connections.
Innovation Solution
A transformer design with a slim coil former and flexible stand-off structure, featuring side-by-side winding arrangement and insulated chambers, allows for reduced overall dimensions, improved cooling, and enhanced insulation, while maintaining efficient electromagnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If annular transformer structures are mounted flat on a substrate with windings wound around an axis orthogonal to the substrate plane, then the transformer can be mounted on PCBs, but the overall dimensions increase markedly as the number of windings increases
Solution Approach 1:
The patent changes the winding axis orientation from orthogonal to the substrate plane (conventional) to parallel with the substrate plane (innovative). This dimensional reorientation allows windings to be arranged side-by-side rather than concentrically, significantly reducing the overall footprint and height of the transformer while maintaining the required number of windings.
Solution Approach 2:
The patent inverts the conventional mounting approach by positioning the transformer with its flat face against the substrate rather than standing on its edge. This inversion, combined with the side-by-side winding arrangement, enables compact integration on PCBs while accommodating multiple windings without proportionally increasing dimensions.
2Volume of moving object
If windings are arranged concentric with respect to one another, then the transformer structure is compact, but automated production and electrical connection become problematical due to small and difficult-to-reach stand-off distances
Solution Approach 1:
By transitioning from concentric to side-by-side winding arrangement, the patent creates adequate stand-off distances and accessible positions for electrical connections. This dimensional change allows automated winding machines to access all winding layers and enables proper pin placement for electrical connections without requiring difficult-to-reach spaces.
Solution Approach 2:
The patent applies different spatial arrangements to different parts of the transformer: the core maintains a compact annular structure, while the windings are arranged side-by-side in a linear sequence. This local differentiation allows the core to remain compact while the windings provide adequate access for automated production and electrical connections.
3Power
If the transformer is designed with increased windings to handle higher power, then the power capacity increases, but the overall dimensions increase markedly
Solution Approach 1:
The side-by-side winding arrangement allows multiple windings to be placed in a linear sequence along the core rather than stacking them concentrically. This enables the transformer to accommodate higher power ratings through increased winding count without proportionally increasing the overall dimensions, as the windings utilize the length of the core rather than adding radial or vertical space.
Solution Approach 2:
The patent employs a flexible stand-off structure that can be adjusted to optimize the spacing between the transformer and the substrate. This dynamic adjustment capability allows for optimized heat dissipation and electrical insulation, enabling the transformer to handle higher power loads without requiring increased physical dimensions.
4Reliability
If the stand-off distance is increased to improve insulation of pins with respect to the core, then the insulation level improves, but the overall height of the transformer increases
Solution Approach 1:
The patent uses a flexible stand-off structure that can be adjusted to provide adequate insulation distance between the pins and the core without requiring a fixed increase in overall height. This dynamic stand-off allows optimization of insulation levels while maintaining compact dimensions through material selection and structural design rather than simply increasing height.
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 solution achieves compact transformer dimensions, efficient heat dissipation, and reduced electromagnetic interference, while enabling automated production and cost-effective manufacturing without protective covers.
Implementation Method 1
a transformer (10), comprising a coil former (100), wound on which are a plurality of windings (Lpri, Ls1, Ls2, Laux)
Implementation Method 2
qualities of flexibility, compactness, efficiency, good dissipation of heat
Implementation Method 3
the transformer may in effect be laid on the substrate or support (for example, a PCB), keeping the top part of the core free so as to facilitate cooling
Data Source
AI summary
A multi-chamber transformer includes windings wound on a coil former, which is provided with transverse flanges that define mutually insulated winding chambers arranged alongside one another in a longitudinal direction of the coil former between two outermost transverse flanges. A transformer core surrounds the windings wound on the coil former, with a first outer surface and a second outer surface that extend on opposite sides with respect to the windings. The coil former includes lateral extensions at the opposite ends of the first outer surface of the core, which carry electrically conductive pins having proximal ends coupled to the windings and distal ends projecting from the lateral extensions of the coil former.