Planar Transformer With Partial Magnet Core for Lower Thickness
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Solution Overview
Problem
Existing transformers with closed magnetic cores have a large overall height and material requirements, leading to increased weight and manufacturing complexity, particularly in planar structures with multiple magnetic bodies that need complex connections.
Innovation Solution
A transformer design featuring a sequence of insulating layers with at least two galvanically separated circuits and a magnetic core that only partially encloses the structure, using a single core part extending parallel to the common plane, which reduces overall thickness and material usage, and optionally includes shielding surfaces to manage stray fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed magnetic core is used to enclose the layered sequence, then magnetic field guidance is improved, but overall thickness and weight increase
Solution Approach 1:
The magnetic core is divided into multiple core parts (first core part, second core part, third core part) that partially enclose the layered sequence rather than forming a complete closed loop. This segmentation allows the magnetic field to be guided effectively through the necessary regions while reducing the total amount of magnetic material required, thereby decreasing overall thickness and weight.
Solution Approach 2:
The invention extracts or removes portions of the magnetic core that would otherwise be required to form a completely closed enclosure. By taking out unnecessary core sections, the design achieves adequate magnetic field guidance for signal transmission while significantly reducing material usage, thickness, and weight.
2Reliability
If multiple magnetic bodies are connected to form a closed core, then magnetic field enclosure is improved, but manufacturing complexity increases
Solution Approach 1:
The magnetic core structure is segmented into discrete core parts that can be manufactured separately and then assembled. This segmentation simplifies the manufacturing process for each individual component while achieving the required magnetic field enclosure through their combined arrangement, reducing overall manufacturing complexity.
Solution Approach 2:
The core parts are designed to be self-aligning or self-positioning during assembly, reducing the need for complex alignment procedures and external fixtures. The magnetic properties and geometric features of the core parts facilitate automatic positioning, thereby simplifying the assembly process.
3Reliability
If a closed magnetic core is used, then magnetic field containment is improved, but material requirements and weight increase
Solution Approach 1:
The magnetic core is segmented into only three essential core parts instead of a complete closed structure. This segmentation maintains sufficient magnetic field containment for effective signal transmission while using less magnetic material, thereby reducing the overall weight of the transformer.
Solution Approach 2:
The invention applies partial action by providing just enough magnetic core material to achieve the necessary field containment for reliable operation, rather than using excessive material to form a complete closed enclosure. This partial core structure is sufficient for the intended application and reduces weight.
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 significantly reduces the overall thickness and weight of transformers while simplifying manufacturing and reducing material costs, while maintaining effective magnetic field guidance and signal transmission.
Implementation Method 1
a common magnetic core which only partially encloses the layered sequence and acts on a number of at least two circuits
Data Source
AI summary
A transformer includes a sequence of insulating layers layered transversely to a common plane, and a plurality of at least two galvanically separated circuits. Each circuit has at least one conductor winding, and a common magnetic core only partially surrounding the layered sequence and acting on the number of the at least two circuits. Each conductor winding is disposed on a respective one of the layers and extends parallel to the common plane. The core optionally has a core portion extending parallel to the common plane and bounds the layered sequence to one side.