Parent-Child Leadframe Transformer Height Reduction
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Solution Overview
Problem
Traditional transformers have a large volume due to the need for space accommodating leadframes and ferrite cores, making them unsuitable for thin electronic products, and stacked PCB transformers are costly and limited to DC/DC conversion due to safety regulations, complicating spatial layout and heat dissipation.
Innovation Solution
A parent-child leadframe type transformer design featuring a ferrite core module, child leadframe with a through hole and coil winding slot, and a parent leadframe with specific openings to reduce height and meet safety regulations, allowing for efficient winding and soldering, and enabling both DC/DC and AC/DC conversions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional transformer structure is used to accommodate leadframe and ferrite core, then the transformer can provide sufficient power conversion capability, but the overall volume becomes relatively large
Solution Approach 1:
The child leadframe is nested within the parent leadframe structure. The child leadframe includes a through hole that allows the ferrite core to pass through, while the parent leadframe provides the outer framework. This nested arrangement allows both leadframes to share the same spatial envelope, significantly reducing the overall transformer volume while maintaining sufficient power conversion capability through the combined winding structures.
2Length of stationary object
If the transformer height is reduced for thin product installation, then the spatial layout improves, but the heat dissipation effect deteriorates
Solution Approach 1:
The invention transitions from a traditional vertical stacking arrangement to a horizontal nested arrangement within the leadframe plane. The parent and child leadframes are arranged side-by-side with the ferrite core passing through the child leadframe's through hole, creating a planar configuration that reduces height while expanding utilization of the horizontal plane. This dimensional change allows heat to dissipate more effectively across the enlarged surface area without requiring increased height.
3Length of stationary object
If stacked PCB structure is used to reduce transformer height, then the overall height decreases, but the manufacturing cost increases
Solution Approach 1:
The invention replaces expensive stacked PCB structures with a more economical leadframe-based construction. The parent and child leadframes are made from standard copper-clad boards that can be manufactured using conventional PCB fabrication processes, eliminating the need for costly multi-layer PCB stacking and complex assembly procedures. This approach achieves height reduction while significantly lowering manufacturing costs through the use of simpler, more readily available materials and processes.
4Length of stationary object
If stacked PCB transformer structure is used, then the transformer can be made thinner, but the application versatility is limited to DC/DC conversion only
Solution Approach 1:
The parent-child leadframe structure provides universal applicability across multiple power conversion applications. The modular design with separate parent and child leadframes allows flexible configuration for different conversion types. By adjusting the winding arrangements on the leadframes and selecting appropriate ferrite core specifications, the same basic structure can be adapted for DC/DC conversion, AC/DC conversion, and other power transformation applications, eliminating the application restrictions of stacked PCB designs.
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 effectively reduces the overall height of the transformer, meets safety requirements, and allows for efficient heat dissipation by optimizing spatial layout, enabling the transformer to be used in thin products and various power conversion applications.
Implementation Method 1
Transformer is an indispensable component of different products having an electric power conversion function
Data Source
AI summary
A parent-child leadframe type transformer includes a ferrite core module, a child leadframe and a parent leadframe. The parent leadframe has a first opening and a second opening on both ends. The length of the second opening is greater than the length of the first opening along the same axial direction. A containing space is defined between the first and second openings. The child leadframe has a coil winding slot and a through hole for installing the ferrite core module. The axial length of the child leadframe falls between the first and second openings, such that the child leadframe and the ferrite core module can be passed through the second opening, but limited by the first opening. The child leadframe, ferrite core module and parent leadframe are positioned to define a parent-child type transformer structure for reducing the overall height and complying with the safety regulation standards.