PCB Transformer Module Layout for Uniform Current Distribution
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Solution Overview
Problem
Existing transformer designs for low-voltage and high-current applications face issues with non-uniform current distribution due to inconsistencies in impedance across winding layers, leading to inefficiencies and increased power consumption in data processing systems.
Innovation Solution
A transformer module with a multi-layer carrier structure featuring horizontal copper foils and connecting copper foils, where the equivalent diameters of winding parts are similar, ensuring uniform current distribution and impedance across multiple windings, and eliminating the need for foil winding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-layer PCB winding is used for transformer, then the transformer can be manufactured with standard PCB processes, but the current distribution becomes non-uniform due to impedance inconsistencies across winding layers
Solution Approach 1:
The patent applies local quality by making the winding structure adaptive to the magnetic core geometry. The winding layers are designed with varying trace widths and spacing in different regions to compensate for impedance variations, ensuring uniform current distribution across all layers while maintaining manufacturability through standard PCB processes
Solution Approach 2:
The patent changes physical parameters of the winding traces (width, spacing, thickness) across different layers to compensate for impedance inconsistencies. By adjusting these parameters locally, the design achieves uniform current distribution while still using standard multi-layer PCB manufacturing processes
2Power
If switching frequency is increased to achieve high power density, then power supply efficiency improves, but power losses increase due to non-uniform current distribution in the transformer
Solution Approach 1:
The patent achieves homogeneity in current distribution across all winding layers by carefully designing the PCB trace geometry. This uniform current distribution reduces resistive losses and enables higher switching frequencies to be used efficiently, thereby achieving high power density without excessive power losses
3Manufacturing precision
If conventional foil winding process is used, then precise winding control can be achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical foil winding process with a PCB-based planar winding structure. This substitution eliminates the complexity of manual or automated winding operations while achieving precise winding geometry through standard PCB fabrication processes, thereby reducing manufacturing complexity while maintaining precision
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 achieves uniform current distribution and reduced power losses, enhancing efficiency and power density in data processing systems while simplifying the winding formation process.
Implementation Method 1
a magnetic core, including at least one magnetic column being at least partially covered by a multi-layer carrier
Implementation Method 2
each of the horizontal copper foils is located on a horizontal wiring layer, and the connecting copper foil is disposed to connect the horizontal copper foils located on different horizontal wiring layers
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A transformer module and a power module are provided. The transformer module includes: a magnetic core, a first winding and a second winding. The magnetic core includes at least one magnetic column at least partially covered by a multi-layer carrier that includes a plurality of horizontal copper foils and connecting copper foils. The horizontal copper foils are located on horizontal wiring layers, and the connecting copper foils are disposed to connect the horizontal copper foils. The first winding and the second winding surround the magnetic column, and the second winding is located outside the first winding. Both the first and second windings are formed by a horizontal copper foil and a connecting copper foil; two ends of the first winding are electrically connected to first and second surface-mounted pins; two ends of the second winding are electrically connected to third and fourth surface-mounted pins,; these pins are disposed on at least one surface of the transformer module.