Planar Transformer With Interleaved Windings And Field-Shaping
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Solution Overview
Problem
Existing line frequency transformers used for power conversion are bulky, costly, and inefficient, making them impractical for high-frequency applications requiring medium voltage isolation.
Innovation Solution
A planar transformer assembly with interleaved primary and secondary windings on a printed circuit board, coupled with a magnetic core and field-shaping apparatus, provides efficient medium voltage isolation at high frequencies, reducing bulkiness and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If line frequency transformers are used for power conversion, then voltage isolation is provided, but the system becomes bulky, heavy, and costly
Solution Approach 1:
The patent changes the operating frequency parameter from line frequency (50/60 Hz) to high frequency (20 kHz or higher). This parameter change enables the use of planar transformers with much smaller magnetic cores and windings, dramatically reducing weight and volume while maintaining the voltage isolation function. The high-frequency operation allows the transformer to achieve the same power transfer capability with significantly reduced physical dimensions.
Solution Approach 2:
The patent transitions from traditional three-dimensional wound transformers to planar two-dimensional transformers fabricated on printed circuit boards. This dimensional change from 3D winding structures to 2D planar structures enables mass production using standard PCB manufacturing techniques, reducing both weight and cost while maintaining electrical performance and isolation characteristics.
2Reliability
If line frequency transformers are used for power conversion, then voltage isolation is provided, but the design complexity and cost increase
Solution Approach 1:
The patent transitions from traditional three-dimensional wound transformers to planar two-dimensional transformers fabricated on printed circuit boards. This dimensional change from 3D winding structures to 2D planar structures enables mass production using standard PCB manufacturing techniques, reducing both weight and cost while maintaining electrical performance and isolation characteristics.
Solution Approach 2:
The patent replaces the mechanical winding process with automated PCB fabrication processes. Instead of manually or mechanically winding copper wire around magnetic cores, the transformer windings are created using standard PCB trace deposition and etching techniques. This substitution dramatically simplifies manufacturing, enables precise control of winding parameters, and facilitates mass production.
3Reliability
If traditional transformer designs are used, then voltage isolation is achieved, but the volume and space requirements increase
Solution Approach 1:
The patent changes the operating frequency parameter from line frequency (50/60 Hz) to high frequency (20 kHz or higher). This parameter change enables the use of planar transformers with much smaller magnetic cores and windings, dramatically reducing volume while maintaining the voltage isolation function. The high-frequency operation allows the transformer to achieve the same power transfer capability with significantly reduced physical dimensions.
Solution Approach 2:
The patent transitions from traditional three-dimensional wound transformers to planar two-dimensional transformers fabricated on printed circuit boards. This dimensional change from 3D winding structures to 2D planar structures dramatically reduces the volume required for the transformer, enabling integration into compact power conversion systems while maintaining electrical isolation.
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 planar transformer design enables flexible and efficient power conversion, reducing weight and improving practicality, while maintaining high voltage isolation and reducing electric field effects, making it suitable for renewable energy integration and other applications.
Implementation Method 1
A planar transformer assembly comprises primary and secondary planar windings coupled with switching devices to generate an isolated output. Each primary and secondary winding is interleaved on layers of a printed circuit board using one or more vias providing electrical connections within the layers of the printed circuit board. The planar transformer also comprises a magnetic core
Implementation Method 2
The field-shaping apparatus is configured to shape an electric field of the isolated output generated by the windings
Data Source
AI summary
Various embodiments of the present disclosure relate to power conversion using a planar transformer assembly that provides medium-voltage isolation at high frequencies. A planar transformer comprises primary and secondary planar windings configured to generate an isolated output. Each primary and secondary winding is interleaved on layers of a printed circuit board using one or more vias within the layers of the printed circuit board. The planar transformer also comprises a magnetic core and a field-shaping apparatus coupled with the printed circuit board. The field-shaping apparatus is configured to shape an electric field generated by the windings. The primary windings can be coupled to a DC source via switching devices while the secondary windings can be coupled via switching devices to one or more DC ports followed by AC inverters configured to generate three single-phase AC outputs for medium voltage applications.