Planar Transformer Adjustable Turns Ratio Modular PCB Design
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Solution Overview
Problem
Planar transformers face challenges in design flexibility due to fixed turns ratios and insulation issues between conductive layers, leading to increased time and cost for new coil patterns and potential electrical discharges.
Innovation Solution
A modular planar transformer design with adjustable turns ratio, utilizing fixed components such as circuit boards with electrically conductive traces and insulating materials, where the turns ratio is adjusted by reorienting the circuit boards and using conductive connectors to maintain electromagnetic coupling while preventing electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric coating is applied to circuit boards to prevent electrical contact between coils, then insulation is provided, but the coating thickness varies near irregular shapes or protrusions and can become porous over time, allowing electrical discharge
Solution Approach 1:
The patent introduces an intermediary insulating structure consisting of raised insulating material positioned between conductive traces on adjacent circuit boards. This raised insulating material acts as a physical barrier and mediator that prevents electrical discharge while maintaining uniform insulation thickness, eliminating the porosity problem associated with thin dielectric coatings.
Solution Approach 2:
The insulating structure is segmented into discrete raised portions positioned at specific locations between conductive traces. Rather than applying a continuous thin coating that varies in thickness, the insulation is divided into separate raised elements that provide consistent insulation where needed most, preventing electrical discharge between adjacent traces.
2Adaptability or versatility
If new printed circuits are fabricated for each coil pattern desired, then design flexibility is achieved, but additional time and cost are incurred
Solution Approach 1:
The patent enables dynamic reconfiguration of the transformer by allowing circuit boards to be reoriented and reconnected in different configurations. Instead of fabricating new static printed circuits for each design change, the same set of circuit boards can be dynamically rearranged to create different coil patterns and turns ratios, reducing fabrication time and cost.
Solution Approach 2:
The transformer is divided into separate modular circuit boards that can be independently arranged and reconfigured. This segmentation allows the same components to be used in different configurations to achieve various coil patterns, eliminating the need to fabricate entirely new printed circuits for each design variation.
3Ease of operation
If circuit boards are positioned adjacent to each other with connector ends aligned, then electrical connection is achieved, but electrical contact between conductive layers may occur without proper insulation
Solution Approach 1:
Raised insulating material is positioned as an intermediary element between the conductive traces on adjacent circuit boards. This intermediary structure maintains the ease of electrical connection through aligned connectors while simultaneously preventing harmful electrical discharge by providing a physical barrier that ensures adequate insulation spacing.
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 compact, lightweight transformers with adjustable turns ratio without requiring new components, enhancing design flexibility and preventing electrical discharges through effective insulation.
Implementation Method 1
first and second circuit boards electrically communicated to comprise at least a second winding, where the first and at least a second windings are operatively electromagnetically coupled
Data Source
AI summary
A planar transformer includes first and second windings that may be comprised of electrically conductive traces etched onto one or more printed circuit boards. The printed circuit boards may be arranged in various orientations so as to change the turns ratio of the planar transformer. In one embodiment, the printed circuit boards are substantially similar and may be electrically connected via connectors that separate the circuit boards. Insulating sleeves may be inserted between the printed circuit boards in an interleaved configuration.