PCB Planar Transformer With Embedded Magnetic Layers for Resonant Switching
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Solution Overview
Problem
Planar transformers exhibit inherently low leakage inductance, limiting the use of zero-volt or resonant switching techniques, which hinders efficiency and size improvements in power electronics.
Innovation Solution
A planar transformer design incorporating magnetic material laminated between windings on a printed circuit board to create additional magnetic flux paths, combined with a magnetic core, enhances leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If planar transformer uses flat windings on PCB instead of wound copper wire, then form factor and integration are improved, but leakage inductance decreases
Solution Approach 1:
Magnetic material is embedded within the PCB layers, nesting magnetic cores inside the planar winding structure. This creates additional magnetic flux paths within the compact PCB form factor while increasing leakage inductance to enable resonant switching techniques.
Solution Approach 2:
The invention transitions from traditional 3D wound windings to 2D planar windings on PCB, then adds magnetic material within the PCB layers to create additional dimensional flux paths. This maintains the compact form factor while compensating for reduced leakage inductance through multi-layer magnetic routing.
2Adaptability or versatility
If planar transformer is made smaller for high-frequency applications, then integration with electronic circuits is improved, but leakage inductance is reduced
Solution Approach 1:
The invention combines PCB material with embedded magnetic materials to create a composite structure. This composite approach allows the transformer to maintain small size for integration while the magnetic material provides enhanced flux paths that increase leakage inductance for resonant switching capability.
3Reliability
If magnetic material is laminated between windings on PCB, then leakage inductance is increased, but device complexity increases
Solution Approach 1:
The invention merges the magnetic material integration directly into the PCB manufacturing process itself. By embedding magnetic material between PCB layers during fabrication rather than adding separate components, the design increases leakage inductance while minimizing additional manufacturing complexity.
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
Increases leakage inductance by up to 10 times, enabling efficient transistor soft switching and reducing electromagnetic interference, suitable for high-frequency applications.
Implementation Method 1
magnetic material laminated directly into printed circuit board windings to provide an alternative flux path and increase leakage inductance
Implementation Method 2
magnetic core disposed over and through the printed circuit board and magnetically coupled to the first planar winding and the second planar winding
Data Source
AI summary
A planar transformer comprising a printed circuit board; a primary planar winding disposed within the printed circuit board; a secondary planar winding disposed within the printed circuit board; a magnetic material disposed within the printed circuit board between the primary planar winding and the secondary planar winding, the magnetic material configured to generate a secondary magnetic flux path; and a magnetic core disposed around and through the printed circuit board and magnetically coupled to the primary planar winding and the secondary planar winding, the magnetic core configured to generate a primary magnetic flux path.