Planar Energy Transfer Element Layout for Low-Noise DC-DC Power Converters
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Solution Overview
Problem
Conventional power converters face challenges in minimizing electromagnetic interference (EMI) and parasitic noise due to the physical separation of transformer components, which can lead to inefficiencies and increased complexity.
Innovation Solution
The proposed solution involves a dc-dc power converter design where the power circuit components are mounted on a stack of circuit layers, including a planar energy transfer element and a magnetic core assembly. This configuration allows the components to be positioned within an area encompassing the windings and connections of the energy transfer element, external to the magnetic core, thereby optimizing electrical connectivity and reducing noise interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If transformer components are physically separated to minimize EMI and parasitic noise, then electromagnetic interference is reduced, but device complexity and inefficiency increase
Solution Approach 1:
The patent merges the transformer components (primary winding, secondary winding, and magnetic core) into a single integrated planar structure fabricated on a printed circuit board. This consolidation eliminates the need for separate discrete transformer components and their associated mounting hardware, thereby reducing device complexity while maintaining EMI minimization through the inherent planar geometry and controlled impedance traces.
2Object-affected harmful factors
If transformer components are physically separated, then electromagnetic interference is reduced, but manufacturing efficiency decreases
Solution Approach 1:
The patent segments the transformer windings into planar trace patterns on different layers of the printed circuit board, with each layer serving a specific winding function. This segmentation allows for automated PCB fabrication processes to manufacture the entire transformer assembly in a single production run, eliminating the need for separate assembly steps for discrete transformer components and thereby improving manufacturing efficiency.
3Ease of manufacture
If conventional discrete transformer components are used, then ease of manufacture is maintained, but electrical connectivity and noise reduction are compromised
Solution Approach 1:
The patent combines the electrical connectivity functions directly into the PCB trace structure, where the same copper traces that provide signal routing also serve as the transformer windings. This merging eliminates additional connection points and potential failure modes associated with discrete component mounting, thereby improving reliability while maintaining ease of manufacture through standard PCB fabrication processes.
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 effectively minimizes EMI and parasitic noise by integrating power circuit components with the energy transfer element, enhancing efficiency and reducing the complexity of the power converter system.
Implementation Method 1
The switched mode power converter converts high voltage related to the unregulated ac input, to a lower voltage related to a constant or stable direct current (dc) output also known as a regulated dc output through an energy transfer element, e.g., a transformer.
Implementation Method 2
a magnetic core assembly. This configuration allows the components to be positioned within an area encompassing the windings and connections of the energy transfer element, external to the magnetic core
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A power converter comprises a stack of circuit layers, a magnetic core, an area of the stack of circuit layers, and power converter circuit components mounted on the stack of circuit layers. The stack of circuit layers has a hole which extends through each of the circuit layers. A portion of the circuit layers form an energy transfer element that comprises an input winding and an output winding. Each winding includes at least one winding layer having a planar winding and connections for electrical connectivity. The magnetic core is positioned within the hole substantially perpendicular to the stack. The area of the stack of circuit layers encompasses the windings and connections for electrical connectivity of the input and output windings. The power converter circuit components are mounted within the area of the stack and external to the magnetic core.