Multilayer Foil Transformer Module for Lower Winding Loss
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Solution Overview
Problem
Existing transformer technologies for low-voltage, high-current applications face issues with uneven current distribution and high winding losses due to inconsistent equivalent diameters and long, centralized output connectors in multi-layer PCB structures, leading to inefficiencies in power density and energy consumption.
Innovation Solution
A transformer module with a foil winding structure, where multiple wiring layers are sequentially disposed on a magnetic core with insulating layers in between, and connectors passing through these layers to achieve even current distribution and reduce winding losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-layer PCB winding structure is used, then power supply capacity is improved, but current distribution uniformity deteriorates
Solution Approach 1:
The patent divides the winding structure into multiple independent PCB layers, with each layer containing partial windings. This segmentation allows current to be distributed across multiple paths rather than concentrated in a single long winding, improving current distribution uniformity while maintaining high power supply capacity through the multi-layer configuration.
Solution Approach 2:
The patent transitions from a single-plane winding layout to a three-dimensional multi-layer PCB structure. By stacking multiple winding layers vertically and connecting them through vias, the design achieves high power density in a compact volume while distributing current across multiple spatial dimensions, thereby improving both power capacity and current distribution uniformity.
2Power
If multi-layer PCB winding structure is used, then power density is improved, but energy loss increases
Solution Approach 1:
The winding is segmented into multiple shorter sections across different PCB layers, replacing a single long centralized winding. This segmentation reduces the total length of current paths and minimizes resistive losses while maintaining the required power density through the compact multi-layer arrangement.
Solution Approach 2:
By utilizing the vertical dimension with multiple PCB layers, the patent achieves high power density without proportionally increasing winding length. The multi-layer configuration allows current to take shorter paths in each layer connected by vias, reducing overall energy loss while maintaining high power density in a compact footprint.
3Device complexity
If centralized output connectors are used, then device complexity is reduced, but current distribution uniformity deteriorates
Solution Approach 1:
The patent distributes output connectors across multiple PCB layers rather than concentrating them at a single location. Each layer has its own connectors that interface with corresponding external connections, segmenting the current extraction points. This distributed connector arrangement maintains relatively simple device complexity while significantly improving current distribution uniformity across the winding structure.
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 foil winding structure ensures even current distribution across the transformer, reducing winding losses and improving power density, thus addressing the inefficiencies in existing transformer technologies.
Implementation Method 1
the equivalent impedances are almost the same. So the current distribution of the winding in a foil structure is almost even which reduces the winding loss greatly
Implementation Method 2
a magnetic core, a first wiring layer, a first insulating layer and a second wiring layer being sequentially disposed on the magnetic core
Data Source
AI summary
The present disclosure provides a transformer module and a power module, wherein the transformer module comprises: a magnetic core, where a first insulating layer and a second wiring layer are sequentially disposed on the magnetic core from inside to outside; a first metal winding, wound around the magnetic core in a foil structure, and comprising a first winding segment formed in the first wiring layer and a second winding segment formed in the second wiring layer; and a second metal winding, wound around the magnetic core in a foil structure, comprising a third winding segment formed in the first wiring layer and a fourth winding segment formed in the second wiring.