Transformer with PCB-Integrated Coils for Rolling Bearings
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Solution Overview
Problem
Existing transformers for data and energy transmission in rolling bearings require complex designs and significant installation space, with limited manufacturing efficiency and high production costs.
Innovation Solution
A transformer design featuring concentric coils on multilayer circuit boards with magnetically conductive layers connected via recesses filled with ferromagnetic material, allowing for magnetic coupling through an air gap, enabling efficient production and integration into rolling bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transformer designs are used for data and energy transmission in rolling bearings, then reliable magnetic coupling is achieved, but the device complexity and installation space requirements increase significantly
Solution Approach 1:
The patent combines the transformer coils directly with the circuit board structure, integrating the magnetic coupling components into the existing PCB layout. This merging eliminates separate transformer assemblies and reduces overall device complexity while maintaining reliable magnetic coupling through direct board-to-board or board-to-component coupling.
Solution Approach 2:
The circuit board serves multiple functions: it provides both the electrical circuit pathways and the structural mounting for the transformer coils. The same PCB layers that carry electrical signals also serve as the magnetic coupling interface, eliminating the need for dedicated transformer components and reducing installation space requirements.
2Reliability
If conventional transformer designs are used for data and energy transmission, then adequate magnetic coupling is achieved, but the installation space and manufacturing complexity increase
Solution Approach 1:
The patent utilizes the third dimension (vertical stacking) by implementing coils on different PCB layers or on opposing faces of the same board. This vertical arrangement enables magnetic coupling through the board thickness rather than requiring lateral spacing, dramatically reducing the footprint area while maintaining adequate magnetic flux linkage.
Solution Approach 2:
The transformer coils are nested within the circuit board structure itself, with inner coils positioned on inner PCB layers and outer coils on outer layers. This nested configuration allows multiple magnetic coupling interfaces to coexist within a compact volume, reducing overall installation space while maintaining coupling efficiency.
3Reliability
If traditional transformer manufacturing methods are used, then adequate magnetic coupling is achieved, but production efficiency decreases and costs increase
Solution Approach 1:
The transformer coils are manufactured as integral parts of the circuit board using standard PCB fabrication processes. The same lamination, etching, and plating steps that create the electrical circuits also create the magnetic coupling structures, eliminating separate manufacturing steps and enabling high-volume production through existing PCB manufacturing infrastructure.
Solution Approach 2:
The patent employs standard PCB materials and manufacturing parameters (copper trace thickness, laminate material properties, etch patterns) to create the transformer coils. By using conventional PCB fabrication parameters rather than specialized transformer manufacturing parameters, the design leverages existing high-efficiency production lines and material supply chains.
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
This design simplifies manufacturing, reduces installation space, and enhances fault tolerance, facilitating cost-effective production and efficient data or energy transmission while allowing for higher operating temperatures.
Implementation Method 1
both coils being situated contactlessly with respect to each other in such a way that they are magnetically coupled
Implementation Method 2
The magnetically conductive layers are magnetically connected to each other with the aid of recesses introduced into the circuit boards and filled with magnetically conductive material
Data Source
AI summary
A transformer (01) for transmitting data and/or energy, including a concentric coil pair with a fixed first coil (04) and a second coil (05) which is mounted so as to be rotatable with respect to the first coil (04), wherein the coils (04, 05) are arranged with respect to one another in such a way that they are magnetically coupled. The transformer (01)—is defined, in particular, by the fact that the first and the second coils (04, 05) are embodied as printed circuits on one multi-layered circuit board (02, 03) each, wherein in each case a magnetically conductive layer (07) is attached to the outer layers of the multi-layered circuit boards (02, 03), wherein the magnetically conductive layers (07) are selectively connected to one another by recesses which are formed in the circuit boards (02, 03) and filled with magnetically conductive material.