PCB Planar Transformer Winding Layout Without Blind Vias
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Solution Overview
Problem
Conventional transformers face challenges in reducing volume while maintaining design flexibility and cost-effectiveness, particularly in applications with limited space.
Innovation Solution
A planar transformer design featuring multiple winding layers with alternating winding directions and conductive holes in extending regions, eliminating the need for buried or blind via holes, enhancing design flexibility and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional transformers use fixed conductive hole configurations, then manufacturing process is simplified, but design flexibility and miniaturization capability are restricted
Solution Approach 1:
The conductive hole configuration is segmented into different types (through-holes, blind vias, buried vias) that can be independently designed and positioned. This allows the transformer design to be divided into modular sections with flexible conductive hole arrangements, enabling customized winding patterns and improved design flexibility without overwhelming complexity.
Solution Approach 2:
The patent transitions from planar 2D winding layouts to 3D multi-layer configurations with conductive holes extending through different depths (through-holes, blind vias, buried vias). This dimensional expansion allows windings to be arranged in three-dimensional space, significantly increasing design flexibility for miniaturization while managing complexity through structured layering.
2Volume of stationary object
If planar transformers are miniaturized for compact applications, then volume is reduced, but manufacturing precision and reliability become more difficult to maintain
Solution Approach 1:
The transformer structure is segmented into multiple layers with conductive holes positioned at different depths and locations. This segmentation allows precise control over each conductive hole's position and dimensions, maintaining manufacturing precision even as overall transformer volume is reduced for compact applications.
Solution Approach 2:
Different regions of the transformer are assigned different conductive hole configurations (through-holes in some areas, blind vias in others, buried vias in specific layers). This local quality approach optimizes manufacturing precision in critical areas while allowing greater flexibility in less critical regions, enabling miniaturization without sacrificing overall precision.
3Adaptability or versatility
If complex via hole configurations are used to improve design flexibility, then manufacturing costs increase
Solution Approach 1:
The conductive hole structure is designed with multi-functionality, where through-holes, blind vias, and buried vias can serve multiple purposes depending on their position and configuration. This universality allows a single manufacturing process to produce various conductive hole types, achieving circuit layout flexibility without proportionally increasing manufacturing costs.
Solution Approach 2:
The patent varies parameters of conductive holes (depth, diameter, position, layer location) to achieve different functional requirements. By changing these parameters within a standardized manufacturing framework, design flexibility is improved while controlling manufacturing costs through process standardization rather than complete customization.
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 allows for increased design flexibility, lower manufacturing costs, and higher yield rates, while maintaining efficient voltage conversion capabilities.
Implementation Method 1
The high voltage side coil receives an alternating current to generate a magnetic field, the low voltage side coil generates an inductive potential difference in response to the magnetic field
Data Source
AI summary
A printed circuit board of a planar transformer includes a first column hole, a second column hole, and a plurality of winding layers. At least one of the winding layers includes a first winding and a second winding connected in series. The first winding surrounds the first column hole and has a first opening direction. The second winding surrounds the second column hole and has a second opening direction. The first opening direction is different from the second opening direction. Consequently, the windings on the plurality of layers may be connected in series through conductive holes of the PCB to increase the number of winding turns.