Planar Transformer Assembly With Encapsulated Core Gap Sealing
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Solution Overview
Problem
Conventional implantable medical device transformers are large and occupy significant space, making it challenging to miniaturize them while maintaining reliability for use in implantable medical devices like implantable cardioverter defibrillators.
Innovation Solution
The development of miniaturized transformer assemblies using a substrate unit sandwiched between magnetic cores, with encapsulant material to permanently position the cores and eliminate air gaps, allowing for smaller package sizes and improved fabrication techniques to achieve custom dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional transformers with separate coil and core members are used, then reliability is maintained, but the transformer occupies a considerable amount of space within the IMD
Solution Approach 1:
The patent merges the coil and core members into a single integrated transformer component. The coil is formed as a spiral pattern directly on the circuit board, and the core members are positioned to engage with this integrated coil structure, eliminating the need for separate conventional transformer assemblies and reducing overall size while maintaining electrical functionality and reliability
Solution Approach 2:
The patent transitions from a three-dimensional wound coil structure to a planar spiral coil pattern on a circuit board. This dimensional change allows the transformer to be flattened and integrated into the PCB layout, significantly reducing the volume occupied by the transformer while maintaining the necessary magnetic coupling and electrical performance
2Volume of moving object
If the IMD is made as small as possible, then patient discomfort is reduced, but space for electronic components becomes limited
Solution Approach 1:
The patent combines multiple components into integrated assemblies. The transformer is integrated with the coil on the circuit board, and the hermetic seal integrates the housing, transformer, and electronic components into a single sealed unit. This merging reduces the overall IMD volume while managing component layout complexity through integrated design
Solution Approach 2:
The circuit board serves multiple functions: it provides the structural substrate for the spiral coil, acts as the transformer core support, provides electrical connections, and serves as part of the hermetic seal structure. This multi-functionality reduces the number of separate components needed, allowing the IMD to be smaller without increasing complexity
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 miniaturized transformer assemblies enable a reduction in size without compromising reliability, allowing for more compact implantable medical devices that can deliver high voltages efficiently for therapies like defibrillation and cardioversion.
Implementation Method 1
an adhesive material may be applied to affix the lower core to the substrate unit
Implementation Method 2
it is necessary to develop high voltages, perhaps 750 volts or more, within the IMD in order to administer a sufficient shock to a patient
Data Source
AI summary
The present disclosure provides methods and techniques associated with a planar transformer for an apparatus. The planar transformers include a substrate carrying electronic components and a continuous core that is formed by distributing the encapsulant material uniformly around the substrate unit to define a consistent cross-sectional area for the magnetic path. The electronic components include primary windings and secondary windings associated with the transformer. In some embodiments, the encapsulant material is molded to seals air gaps to the substrate unit.