Planar Primary Winding Transformer for Compact PCB Integration
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Solution Overview
Problem
Conventional transformers, including current sense transformers, are physically large due to their electromagnetic nature, which limits their miniaturization and integration into solid-state components, making them a limiting factor in the miniaturization of electronic systems and power converters.
Innovation Solution
A transformer design where one or more conductive traces on a printed circuit board serve as a winding, with a magnetic core and secondary winding disposed within the plane of the board, allowing for a low-profile construction that minimizes physical size and series resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional transformer design with discrete windings and magnetic core is used, then magnetic coupling and electrical isolation are maintained, but physical size and height increase
Solution Approach 1:
The patent merges the transformer winding with the printed circuit board trace, eliminating the need for separate discrete windings. The primary winding is formed by conductive traces on the PCB, while the secondary winding uses a wire wrapped around a bobbin, integrating multiple functions into a compact structure that reduces overall transformer size and height.
Solution Approach 2:
The patent transitions from traditional three-dimensional wire windings to a planar two-dimensional trace configuration for the primary winding on the PCB. This dimensional change allows the transformer to achieve a low-profile construction with reduced height while maintaining the necessary magnetic coupling through the vertical magnetic core.
2Volume of moving object
If transformer miniaturization is pursued, then integration into compact electronic systems improves, but series resistance and manufacturing difficulty increase
Solution Approach 1:
The printed circuit board serves multiple functions: it provides mechanical support, electrical connections, and forms the primary winding itself. This multi-functionality eliminates the need for separate winding components and simplifies the manufacturing process, making the transformer easier to produce while maintaining miniaturization benefits.
Solution Approach 2:
The PCB trace automatically forms the primary winding with inherent low series resistance due to its direct conductive path, eliminating the need for additional resistance-compensation measures. The structure serves itself by using the existing PCB conductivity to achieve the winding function, simplifying manufacturing.
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 enables efficient miniaturization of transformers, reducing their height and form factor, facilitating the integration of transformers into compact electronic systems without compromising magnetic coupling or electrical isolation.
Implementation Method 1
Electromagnetic transformers have long been staple components in many electrical and electronic systems
Implementation Method 2
a magnetic core has a first leg inserted through a hole in the printed circuit board at a location near the primary winding conductor traces
Data Source
AI summary
A transformer, such as a current sense transformer, in which conductive traces disposed within a printed circuit board serve as the primary winding of the transformer. The transformer also includes a secondary winding, for example wound around a hollow pin of a bobbin, through which a leg of a magnetic core is disposed. The magnetic core leg, and in some embodiments also all or a part of the secondary winding, is inserted into a through-hole in the printed circuit board that is surrounded by the primary winding traces.