Planar Transformer Winding for Odd Turn Ratio
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Solution Overview
Problem
Traditional winding modes for planar transformers with odd turn ratios result in asymmetry of magnetic fields and reduced efficiency due to large window areas and multi-layer structures, increasing volume and design costs.
Innovation Solution
The method involves connecting inner winding wires in parallel and then in series to a narrower outer winding wire, forming a primary winding, which improves the distribution of magnetic fields and enhances the operating efficiency of the planar transformer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional single-layer or asymmetric multi-layer winding modes are used for planar transformers with odd turn ratio, then the winding structure is simple to manufacture, but the window area of magnetic core must be large and PCB layers must be increased, resulting in increased volume and design cost
Solution Approach 1:
The primary winding is segmented into inner winding wires and outer winding wire, with inner wires connected in parallel and then in series with the outer wire. This segmentation allows the odd turn ratio to be achieved without increasing the number of PCB layers or magnetic core window area, thus reducing transformer volume while maintaining manufacturability
Solution Approach 2:
The patent transitions from traditional single-layer or asymmetric multi-layer winding to a four-layer symmetric structure. By utilizing multiple layers symmetrically arranged around the magnetic core, the patent achieves odd turn ratio without increasing overall transformer volume, effectively using dimensional arrangement to resolve the contradiction
2Manufacturing precision
If asymmetric multi-layer winding structures such as 2+1 structures are used, then the odd turn ratio is achieved, but asymmetric structures cause uneven distribution of magnetic fields and reduce transformer operating efficiency
Solution Approach 1:
The patent deliberately introduces asymmetry in the winding configuration to achieve odd turn ratio, but compensates by creating a symmetric overall structure with four layers. The inner parallel wires and outer series wire are arranged symmetrically around the magnetic core, ensuring uniform magnetic field distribution while achieving the required turn ratio precision
Solution Approach 2:
Different parts of the winding structure have different properties: inner winding wires are connected in parallel while the outer winding wire is connected in series. This local differentiation in connection mode allows precise control of turn ratio while the overall symmetric arrangement maintains uniform magnetic field distribution, reducing energy loss
3Ease of manufacture
If traditional winding modes are used with odd turn ratio, then the manufacturing process is simple, but the magnetic field distribution becomes asymmetric and operating efficiency decreases
Solution Approach 1:
The primary winding is divided into inner parallel-connected wires and an outer series-connected wire, creating a segmented structure that achieves odd turn ratio. This segmentation maintains manufacturing simplicity while ensuring symmetric magnetic field distribution and high operating efficiency through balanced electromagnetic characteristics
Solution Approach 2:
The patent merges multiple winding wires into a unified primary winding structure where inner wires are parallel-connected and then series-connected to the outer wire. This merging creates a symmetric four-layer configuration that improves operating efficiency while keeping the manufacturing process straightforward
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 approach allows for a well-distributed magnetic field and improved operating efficiency of planar transformers by optimizing the winding configuration, reducing the volume and design costs associated with traditional methods.
Implementation Method 1
The winding of most planar transformers is performed on printed circuit boards (PCBs)... parallelly connecting the inner winding wires on the top layer to the inner winding wire on the bottom layer, and then serially connecting the parallel-connected inner winding wires to an outer winding wire, so as to form a primary winding
Data Source
AI summary
A method for planar transformer with an odd turn ratio includes: determining a turn ratio and winding parameters of a transformer to be manufactured; if the turn ratio is odd, determining that there is respectively one winding turn on a first middle layer and a second middle layer and two winding turns on a top layer and a bottom layer; determining widths of winding wires on marginal layers as well as widths of winding wires on middle layers; winding and parallelly connecting an inner winding wire on the top layer to an inner winding wire on the bottom layer, and then serially connecting the parallel-connected inner winding wires to an outer winding wire to form a primary winding; and parallelly connecting the winding wire on the first middle layer to the winding wire on the second middle layer to form a secondary winding, so as to obtain the transformer.