Planar Transformer Integrated Ring Core Galvanic Isolation
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Solution Overview
Problem
Existing planar transformers for intrinsically safe electrical circuits are bulky and lack a compact design, which is a challenge for installation in explosion protection environments where space is limited.
Innovation Solution
A planar transformer with a sandwich-type layer structure and a ring-type magnetic core integrated within an insulating inner layer, allowing for galvanic isolation between electrical circuits and enabling a compact, flat design that meets the required isolation distances for intrinsically safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional planar transformer designs are used, then galvanic isolation is achieved, but the installation size and height are excessive
Solution Approach 1:
The magnetic core is integrated directly into the insulating inner layer of the sandwich-type layer structure, nesting the core within the insulation framework. This eliminates the need for separate core housings and reduces overall transformer volume while maintaining galvanic isolation through the insulating layer architecture.
Solution Approach 2:
The patent transitions from conventional three-dimensional transformer structures to a planar, two-dimensional optimized design with a sandwich-type layer structure. The magnetic core is positioned in the vertical dimension within the insulating layer, allowing compact horizontal footprint while maintaining required isolation distances through vertical layering.
2Reliability
If minimum isolation distances are increased for higher safety levels, then intrinsically safe operation is improved, but the transformer geometry becomes more complex and larger
Solution Approach 1:
The transformer is divided into distinct functional layers in a sandwich structure: conductive layers for windings, insulating inner layers for galvanic isolation, and insulating outer layers for additional protection. This segmentation allows each layer to be optimized independently for its specific function, simplifying the overall geometric design while meeting isolation distance requirements.
Solution Approach 2:
The insulating inner layer serves multiple functions simultaneously: it provides galvanic isolation between primary and secondary circuits, houses the magnetic core to reduce size, and establishes the required creepage and clearance distances. This multi-functionality reduces geometric complexity compared to separate components for each function.
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 compact design of the planar transformer with a ring-type magnetic core integrated into the insulating inner layer ensures effective galvanic isolation, meeting the necessary separation and creepage distances for intrinsically safe operation, making it suitable for explosion protection environments with reduced installation height and improved reproducibility.
Implementation Method 1
at least one ring-type magnetic core (140) which has a hole and acts at least on the first electrical circuit (150) and on the second electrical circuit (160)
Implementation Method 2
a conductor (151, 161) of the first electrical circuit (150) and a conductor (151, 161) of the second electrical circuit (160) each have a winding (152, 162) with at least one winding turn (153, 163)
Implementation Method 3
at least one insulating inner layer (130) disposed between the two conductive layers
Data Source
AI summary
A planar, in particular intrinsically safe transformer, having: a sandwich-type layer structure having a plurality of layers extending horizontally and arranged vertically on top of one another, including a first and a second conductive layer and at least one insulating inner layer disposed between the two conductive layers, a plurality of electrical circuits, wherein a first electrical circuit and at least a second electrical circuit are galvanically isolated from each other; and at least one ring-type magnetic core having a hole, which acts at least on the first electrical circuit and the second electrical circuit. The core is arranged within the at least one insulating inner layer, a conductor of the first electrical circuit and a conductor of the second electrical circuit each have a winding with at least one winding turn, and the at least one winding turn of the first electrical circuit and the at least one winding turn of the second electrical circuit each run along the first conductive layer and along the second conductive layer and through the at least one insulating inner layer and through the hole of the core.