Planar Transformer Nesting in PCB Recess for Isolation
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Solution Overview
Problem
In narrow electrical devices like isolation amplifiers, there is a challenge in maximizing the use of available space within the housing while meeting safety standards for planar transformers, which often require a minimum circuit board thickness to ensure isolation distances, limiting the overall height available for mounting components.
Innovation Solution
The electrical module design incorporates a main circuit board with a recess to accommodate an add-on circuit board, allowing the planar transformer to be positioned separately, thus optimizing space usage and meeting safety requirements by using a combination of main and add-on circuit boards with varying thicknesses and step-like connections for mechanical and electrical interlocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the planar transformer is mounted directly on the main circuit board to maximize space utilization, then the available volume is optimized, but the isolation distance requirements cannot be met
Solution Approach 1:
The circuit board is segmented into a main circuit board and a separate transformer circuit board. The transformer is mounted on the transformer circuit board which has sufficient thickness to provide the required isolation distance, while the main circuit board handles other components. This segmentation allows both space optimization and compliance with isolation distance requirements.
Solution Approach 2:
The transformer circuit board is nested within a recess of the main circuit board, creating a stepped configuration. This nesting allows the transformer to be positioned in the available space while maintaining the necessary isolation distance through the thickness of the transformer circuit board, effectively solving the contradiction between space utilization and isolation requirements.
2Reliability
If the circuit board thickness is increased to meet isolation distance requirements, then safety standards are satisfied, but the overall height of the device increases
Solution Approach 1:
The transformer circuit board is nested within a recess of the main circuit board, creating a stepped configuration. This allows the transformer to be positioned in the available space while maintaining the necessary isolation distance through the thickness of the transformer circuit board, effectively solving the contradiction between space utilization and isolation requirements.
Solution Approach 2:
Instead of increasing the overall height of the device, the solution utilizes the horizontal dimension by creating a stepped configuration with a recess. The transformer circuit board extends horizontally from the main circuit board, allowing sufficient thickness for isolation distance without increasing the vertical profile of the device.
3Reliability
If a single thick circuit board is used to ensure isolation distance, then safety requirements are met, but the mounting height for other components is reduced
Solution Approach 1:
The circuit board is segmented into a main circuit board and a separate transformer circuit board. The transformer is mounted on the transformer circuit board which has sufficient thickness to provide the required isolation distance, while the main circuit board handles other components. This segmentation allows both space optimization and compliance with isolation distance requirements.
Solution Approach 2:
The transformer circuit board has locally increased thickness specifically in the region where the transformer is mounted to provide the required isolation distance. Other regions of the main circuit board maintain their original thickness, preserving mounting height for other components. This local quality change ensures isolation requirements are met without compromising overall device functionality.
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 design enables the use of the available space efficiently while ensuring the planar transformer meets intrinsic safety standards, allowing for a compact and safe electrical module with improved mounting height utilization.
Implementation Method 1
The transformer property also makes it possible to interconnect circuits of different AC voltage levels
Implementation Method 2
The add-on circuit board and the main circuit board can be connected to one another in a manner providing both mechanical and electrical connection, in particular by means of a step-like geometry
Data Source
AI summary
An electric module with a planar transformer has a housing with an interior having an internal length and an internal height. The electric module additionally has a main printed circuit board with a first thickness, the main printed circuit board being equipped with at least one electronic component. The planar transformer is arranged on an additional printed circuit board with a second thickness, and the main printed circuit board has a recess which receives the additional printed circuit board. Additionally, the main printed circuit board and the additional printed circuit board are connected together via a connection.