Planar Transformer Assembly With Integrated Windings for Compact Cooling
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Solution Overview
Problem
Existing electrical transformers are bulky due to conventional coil structures around a ferromagnetic core, and there is a need for a more compact and efficiently manufacturable planar transformer design that addresses heating and cooling constraints.
Innovation Solution
A planar electrical assembly comprising a substrate with integrated primary and secondary conductive windings, where the secondary windings are held by prepreg material, and a ferromagnetic core is added for magnetic coupling, allowing for a monolithic structure with improved cooling and electromagnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional coil structures around a ferromagnetic core are used, then electromagnetic transformation function is achieved, but the transformer becomes bulky
Solution Approach 1:
The patent transitions from conventional three-dimensional coil windings around a core to planar two-dimensional winding structures fabricated on substrates. The primary and secondary windings are created as planar patterns on separate substrates that are then stacked and assembled, eliminating the need for volumetric coil winding around a ferromagnetic core while maintaining the electromagnetic transformation function through planar magnetic coupling.
2Volume of moving object
If planar coils are used to reduce spatial bulk, then volume is reduced, but manufacturing complexity increases due to multiple assembly steps
Solution Approach 1:
The patent combines multiple manufacturing operations into integrated substrate fabrication processes. The primary and secondary windings are fabricated as planar patterns directly on substrates using standard PCB or semiconductor manufacturing techniques, eliminating the need for separate coil winding, insulation application, and assembly steps. The substrates themselves provide both mechanical support and electrical insulation, merging structural and functional elements into unified components.
3Productivity
If multiple separate components are assembled to form the transformer, then flexibility in assembly is achieved, but production time increases
Solution Approach 1:
The patent performs preliminary fabrication of primary and secondary windings as planar patterns on separate substrates before final assembly. These substrates are prepared in advance using high-volume manufacturing techniques, with all winding patterns, insulation layers, and structural elements already in place. This preliminary preparation enables rapid final assembly through simple stacking and bonding operations, significantly increasing production speed while maintaining manufacturing flexibility.
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 results in a compact, easily manufacturable planar transformer with enhanced cooling capabilities and improved electromagnetic performance, facilitating industrial-scale production.
Implementation Method 1
a ferromagnetic core added to the electrical assembly so as to magnetically couple the primary electrically conductive windings with the secondary electrically conductive windings
Data Source
AI summary
A planar electrical assembly includes a substrate, in particular formed from sheets of prepreg. The substrate includes, incorporated into the mass of the substrate, at least one primary electrically conductive winding, in a first layer of the substrate, forming at least part of a primary circuit for an electrical transformer. At least one secondary electrically conductive winding is provided in a second layer of the substrate superimposed on the first layer and forming at least part of a secondary circuit for the electrical transformer.