Integrated Planar Transformer with Embedded Ferrite Core
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Solution Overview
Problem
Current communication connectors face challenges in integrating planar magnetic components due to hand-wound magnetics, which result in poor repeatability, performance, and increased manufacturing costs, especially in high-frequency applications where impedance control and compact designs are necessary for emerging protocols like 40G and 100G Ethernet.
Innovation Solution
The integration of wideband planar transformers with ferrite material embedded in a rigid planar substrate, surrounded by inter-wound conductors and non-conductive elastic material, using conductive vias for connectivity, and featuring a center tap for impedance matching and EMI suppression, allowing for compact and efficient electromagnetic component design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hand-wound magnetic units are integrated into connector housing, then magnetic isolation and EMI suppression are achieved, but manufacturing time increases and repeatability deteriorates
Solution Approach 1:
The magnetic core is divided into multiple segmented pieces that can be separately manufactured and then assembled into the connector housing. This segmentation allows for automated manufacturing of individual magnetic segments while maintaining the overall magnetic isolation performance when assembled together.
Solution Approach 2:
The patent combines the magnetic core segments with the connector housing structure by integrating them into a single assembled unit. The housing itself is designed to accommodate and position the magnetic segments, merging the structural and magnetic isolation functions into one integrated component.
2Reliability
If hand-wound magnetic units are used, then magnetic functionality is provided, but manufacturing precision and spacing control worsen
Solution Approach 1:
By segmenting the magnetic core into standardized pieces with defined dimensions, the patent enables precise positioning and spacing control during assembly. Each segment can be manufactured with tight tolerances and then positioned accurately within the housing using molded features or mounting structures.
Solution Approach 2:
The patent replaces the manual hand-winding mechanical process with automated molding and assembly processes. The magnetic segments are molded with precise geometries and then assembled using automated placement equipment, eliminating the variability inherent in hand-winding operations.
3Reliability
If hand-wound magnetics are integrated into connectors, then electromagnetic isolation is achieved, but manufacturing cost increases
Solution Approach 1:
Segmenting the magnetic core allows for more efficient manufacturing and assembly. Individual magnetic segments can be molded using cost-effective injection molding processes and then assembled in batches, reducing labor costs compared to hand-winding each magnetic unit individually.
Solution Approach 2:
By integrating the magnetic segments directly into the connector housing assembly, the patent eliminates separate manufacturing and assembly steps for discrete magnetic components. The housing and magnetic segments are assembled together as a single unit, reducing overall manufacturing complexity and cost.
4Reliability
If hand-wound magnetic units are used, then basic magnetic function is provided, but impedance control and performance at high frequencies deteriorate
Solution Approach 1:
The patent replaces the imprecise hand-winding mechanical process with automated molding and assembly processes that provide consistent geometric precision. This enables better control of electrical characteristics including impedance, as the automated processes maintain tighter tolerances on critical dimensions.
Solution Approach 2:
The segmented magnetic core design allows for optimized geometry and positioning that can be precisely controlled during manufacturing. This segmentation enables better management of magnetic flux paths and electrical characteristics, improving impedance control and high-frequency performance compared to irregular hand-wound configurations.
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 solution enables low-cost, high-performance, and compact electromagnetic components with controlled parasitic inductance and leakage, reducing EMI and enhancing manufacturing efficiency, suitable for high-density communication systems.
Implementation Method 1
a ferrite material embedded in the fully-cured and rigid planar substrate
Implementation Method 2
inter-wound conductors disposed around the embedded ferrite material
Implementation Method 3
bonding layers include an insulating adhesive
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(c)
Figure 2(d)~2(e)
AI summary
The current invention provides an integrated planar transformer and electronic component that includes at least one wideband planar transformer disposed in a planar substrate, where each wideband planar transformer includes a planar substrate in a fully-cured and rigid state, a ferrite material embedded in the planar substrate, where the ferrite material is enveloped in an elastic and non-conductive material, inter-wound conductors disposed around the embedded ferrite material, where top and bottom conductors are bonded by an insulating adhesive. The top and bottom conductors are connected in an inter-connected pattern by conductive vias disposed on each side of the ferrite material and span through the layers to the conductors. The planar transformer further includes at least one center tap connected to at least one inter-wound conductor. The integrated planar transformer and electronic component further includes at least one electronic component connected to at least one terminal of the wide-band planar transformer.