Planar Transformer Core Segmentation for Lower Winding Loss
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Solution Overview
Problem
Planar transformers face challenges in reducing winding loss due to air-gap inductance, which leads to uneven current density distribution and increased AC resistance, limiting their efficiency and power density in miniaturized applications.
Innovation Solution
The design incorporates a planar transformer structure with a first and second magnetic core and a circuit board, featuring separation components made of electrical insulation material strategically placed between the magnetic cores to reduce air-gap magnetic flux cutting the windings, thereby minimizing winding loss and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If planar transformer is used to reduce volume, then power density increases, but air-gap inductance causes uneven current density distribution and increased winding loss
Solution Approach 1:
The magnetic core is divided into multiple segments separated by insulation components. This segmentation prevents magnetic flux from cutting across the windings at air gaps, reducing eddy currents and winding loss while maintaining the compact planar structure
Solution Approach 2:
Insulation components are introduced as intermediary elements between magnetic core segments. These intermediaries block the path of air-gap magnetic flux, preventing it from cutting the windings and generating harmful eddy currents, thus reducing winding loss
2Area of stationary object
If planar transformer structure is adopted, then space utilization improves, but edge magnetic flux and bypass magnetic flux increase causing higher AC resistance
Solution Approach 1:
The magnetic core is segmented with insulation components positioned at critical locations where edge and bypass magnetic flux paths occur. This segmentation interrupts these flux paths, reducing the cutting effect on windings and lowering AC resistance while preserving the compact planar geometry
3Loss of energy
If magnetic core segments are separated by insulation components, then air-gap magnetic flux cutting windings is reduced, but device complexity increases
Solution Approach 1:
Thin insulation components are used to separate magnetic core segments. These thin films effectively block air-gap magnetic flux from cutting the windings while adding minimal structural complexity and maintaining the compact planar transformer design
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 configuration significantly increases power density, reduces leakage inductance, and lowers voltage stress on power switches, while maintaining high temperature resistance and easy heat dissipation, making it suitable for high-efficiency and miniaturized power supply requirements.
Implementation Method 1
the high-voltage-side coil receives alternating current (AC) power to generate a magnetic field, and the low-voltage-side coil generates an induced potential difference in response to the generated magnetic field
Implementation Method 2
the air-gap inductance affects the winding loss. Since the edge magnetic flux and bypass magnetic flux cut the winding, eddy currents are generated on the windings
Data Source
AI summary
A planar transformer includes a first magnetic core, a second magnetic core, and a circuit board. The first magnetic core includes a base, a first magnetic column, a second magnetic column, and a third magnetic column. The circuit board includes a first side, a second side, and a through hole. The through hole is sleeved on the second magnetic column, and the first side and the second side are protruding from the first magnetic core. The first magnetic core is connected with the second magnetic core, and the circuit board is disposed between the first magnetic core and the second magnetic core. At least one separation component is disposed between the first magnetic core and the second magnetic core, or the first magnetic core and/or the second magnetic core have a plurality of separation components.