Hybrid PCB Transformer Layout for Faster Isolated Power Conversion
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Solution Overview
Problem
Conventional transformers for high input voltage to low output voltage conversions are costly, time-consuming to manufacture, and inefficient due to complex dielectric layer requirements and high material usage, especially in planar transformer designs on printed circuit boards.
Innovation Solution
A hybrid transformer design featuring surface-mounted wire coils on opposing sides of a printed circuit board with a core extending through the coils and PCB, utilizing a header for electrical coupling, which reduces material usage and manufacturing time while improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional planar transformers with thick dielectric layers are used for high voltage isolation, then safety requirements are met, but manufacturing time increases to six weeks and complexity increases
Solution Approach 1:
The transformer is divided into separate modular components: pre-assembled coil assemblies with integrated insulation, a core assembly, and a PCB substrate. This segmentation allows parallel manufacturing of components and eliminates the time-consuming process of growing thick dielectric layers, while maintaining safety isolation through the modular design with inherent clearance and creepage distances.
Solution Approach 2:
Coil assemblies are pre-assembled with insulation and termination points before being mounted on the PCB. This preliminary assembly allows insulation and safety clearances to be established in advance during coil fabrication, rather than requiring time-consuming dielectric layer growth after PCB assembly, thereby reducing overall manufacturing time while maintaining safety requirements.
2Reliability
If conventional planar transformers with thick dielectric layers are used for high voltage isolation, then safety requirements are met, but device complexity and material usage increase
Solution Approach 1:
The transformer is divided into separate modular components: pre-assembled coil assemblies with integrated insulation, a core assembly, and a PCB substrate. This segmentation allows each component to be manufactured and tested independently, reducing overall device complexity and facilitating easier assembly and maintenance.
Solution Approach 2:
The PCB serves as an intermediary substrate that mechanically supports and electrically connects the coil assemblies and core. This intermediary structure provides a standardized platform for assembly, reducing manufacturing complexity by eliminating the need for complex integrated structures while maintaining safety isolation through proper design of clearance and creepage distances on the PCB.
3Productivity
If surface mounted wire coils are used instead of PCB-integrated coils, then manufacturing time is reduced and cost decreases, but electrical coupling complexity may increase
Solution Approach 1:
The coil assemblies are segmented as separate modular units with pre-established electrical terminals and insulation. This segmentation enables standard surface-mount assembly processes to be used, significantly reducing manufacturing time and cost compared to PCB-integrated coils, while the standardized terminals simplify electrical coupling to the PCB rather than increasing complexity.
Solution Approach 2:
Standard surface-mount coil assemblies with conventional wire leads and insulation structures are used instead of custom PCB-integrated coil structures. These standardized components are readily available and use established manufacturing processes, reducing both cost and manufacturing time while maintaining electrical performance through proper design of the mounting and coupling 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 hybrid transformer design enhances power density, decreases costs, accelerates time-to-market, and improves efficiency by facilitating easier customization and reduced power dissipation compared to conventional transformers.
Implementation Method 1
A transformer is conventionally utilized to increase or decrease the alternating voltages in electric power applications
Data Source
AI summary
Illustrative embodiments of hybrid transformers, power supplies, and methods relating to the same are disclosed. In at least one embodiment, a hybrid transformer includes first and second wire coils arranged on opposing surfaces of a printed circuit board (PCB), a core extending through the PCB, wherein the first and second coils are each wound around the core, and at least one header electrically coupling one of the first and second wire coils to the PCB.