Planar Transformer Core With Integrally Formed Heat Sink Fins
Solution Overview
Problem
Planar transformers face challenges in thermal management due to their compact size, leading to overheating issues, and existing heat sink solutions are either ineffective or increase manufacturing complexity and cost.
Innovation Solution
Integrally forming heat sink fins with the core of the planar transformer, eliminating the need for a separate thermal interface and allowing for enhanced heat transfer through convection, while maintaining the compact design and avoiding additional manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate heat sink is mounted to the planar transformer, then thermal management is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The heat sink is integrated directly into the core structure of the planar transformer, merging two previously separate components (core and heat sink) into a single unified structure. This eliminates the need for separate mounting steps and thermal interface materials, thereby improving thermal management while reducing device complexity and manufacturing steps.
2Loss of energy
If a thermal interface is used between core and heat sink, then heat transfer is facilitated, but manufacturing complexity increases
Solution Approach 1:
By integrating the heat sink directly into the core structure, the invention eliminates the thermal interface layer that would otherwise be required between separate components. This direct integration maintains efficient heat transfer while eliminating the complexity of installing and maintaining thermal interface materials.
3Volume of moving object
If the transformer is made compact, then space constraints are satisfied, but thermal management becomes difficult
Solution Approach 1:
The integration of the heat sink into the core structure allows for efficient thermal management within the compact transformer volume. By combining the magnetic core and heat dissipation structure into one unified component, the design achieves effective heat dissipation without increasing the overall transformer size.
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 solution provides improved thermal performance by creating an uninterrupted thermal path for heat dissipation, effectively managing heat without increasing the transformer's volume or manufacturing complexity, thus preventing overheating and reducing costs.
Implementation Method 1
allowing for enhanced heat transfer through convection
Implementation Method 2
creating an uninterrupted thermal path for heat dissipation
Data Source
AI summary
A planar transformer comprises a laminate substrate having an opening with metal traces wound thereabout forming a primary and a secondary winding, a core configured to fit inside the opening to enclose the laminate substrate. At least one heat sink fin is integrally formed with the top, bottom or both sides of the core. A method of forming a planar transformer comprises laminating a substrate having an opening with metal traces wound thereabout forming a primary and a secondary winding, fitting a core inside the opening, and enclosing the laminate substrate. One of the top, bottom or both sides of the core include one or more heat sink fins.