PCB Planar Transformer Windings With Embedded Conductive Sheets

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Solution Overview

Problem

Conventional planar transformers face issues with high equivalent resistance, low current carrying capacity, high copper loss, and manufacturing complexity due to thickness limitations of copper foil and winding design, limiting their application in high-power scenarios.

Innovation Solution

A planar transformer design with embedded conductive sheets within printed circuit boards, enclosed by magnetic cores, and a power supply device incorporating planar transformers with improved conductive sheet thickness and insulation, reducing DC resistance and enhancing current handling capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional planar transformers use printed circuit board winding design, then the transformer can be manufactured and assembled more easily, but the copper foil thickness is limited resulting in high equivalent resistance, low current carrying capacity, and high copper loss

Engineering Contradiction:

Improvemanufacturing and assembly easeVSAvoidcurrent carrying capacity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent combines copper foil and copper sheet in a single winding structure. The copper foil provides flexibility and integration with the PCB, while the copper sheet adds thickness and cross-sectional area. This composite approach maintains the ease of PCB manufacturing while significantly improving current carrying capacity and reducing equivalent resistance and copper losses.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional planar transformers use printed circuit board winding design, then the transformer can be manufactured and assembled more easily, but the equivalent resistance is high and copper loss is high

Engineering Contradiction:

Improvemanufacturing and assembly easeVSAvoidcopper loss

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

By combining copper foil and copper sheet, the patent increases the effective cross-sectional area of the winding conductor. This reduces the equivalent resistance of the winding, thereby reducing I²R copper losses while maintaining the PCB-based manufacturing approach that ensures ease of production.

Inventive Principle:

Principle #40Composite materials

3Length of stationary object

If conventional planar transformers use printed circuit board winding design, then the transformer possesses thinner size and excellent repeatability, but the current handling capacity is limited due to copper foil thickness limitation

Engineering Contradiction:

Improvetransformer thicknessVSAvoidcurrent handling capacity

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The patent maintains the thin profile characteristic of planar transformers by using PCB-based construction, but enhances current handling capacity by incorporating copper sheet material that increases the conductor cross-sectional area without significantly increasing the overall transformer thickness.

Inventive Principle:

Principle #40Composite materials

4Manufacturing precision

If conventional planar transformers use printed circuit board winding design, then the transformer possesses excellent repeatability and consistency, but the equivalent resistance is high

Engineering Contradiction:

Improverepeatability and consistencyVSAvoidequivalent resistance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent combines copper foil and copper sheet in a controlled manner within the PCB winding structure. This composite construction maintains the repeatability and consistency advantages of PCB manufacturing while reducing equivalent resistance through increased conductor cross-sectional area from the copper sheet component.

Inventive Principle:

Principle #40Composite materials

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 new design reduces equivalent resistance, increases current density, and improves efficiency, enabling high-power applications while simplifying manufacturing and assembly processes.

Implementation Method 1

Each of the at least one primary winding unit includes a printed circuit board and a first conductive sheet. The first conductive sheet is embedded within the printed circuit board.

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

The magnetic core assembly includes at least one magnetic core. In addition, at least a portion of the at least one primary winding unit and at least a portion of the at least one secondary winding unit are enclosed by the magnetic core assembly.

Methodology Applied

Scientific EffectMagnetic Field: Magnetic Field

Data Source

PatentUS20260011479A1Planar transformer and power supply device with same

Publication Date: 2026.01.08 DELTA ELECTRONICS INC(CN)

AI summary

A planar transformer and a power supply device with the planar transformer are provided. The planar transformer includes a primary winding assembly, a secondary winding assembly and a magnetic core assembly. The primary winding assembly includes at least one primary winding unit. Each of the at least one primary winding unit includes a printed circuit board and a first conductive sheet. The first conductive sheet is embedded within the printed circuit board. The secondary winding assembly includes at least one secondary winding unit. The magnetic core assembly includes at least one magnetic core. In addition, at least a portion of the at least one primary winding unit and at least a portion of the at least one secondary winding unit are enclosed by the magnetic core assembly.