Miniature Planar Transformer PCB Integration
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Solution Overview
Problem
Existing miniature transformers and inductors occupy significant space on circuit boards and are costly to manufacture, limiting their use in high voltage applications.
Innovation Solution
The development of miniature inductive devices integrated into printed circuit boards (PCBs) using a ferrite core with conducting layers and through holes, allowing for compact design and efficient manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete components are used to manufacture small transformers, then the transformers can be manufactured, but they occupy significant space on the circuit board and are expensive to manufacture
Solution Approach 1:
The patent merges the transformer structure directly into the PCB by integrating windings, magnetic core, and circuit board into a single unified component. The windings are formed as conductive traces on the PCB layers, eliminating the need for separate discrete transformer components and reducing overall space occupation while lowering manufacturing costs through standardized PCB production processes.
Solution Approach 2:
The patent utilizes the third dimension by forming windings that extend through multiple PCB layers with conductive vias connecting different layers. This vertical stacking approach allows the transformer to occupy minimal surface area on the circuit board while maintaining the necessary winding turns and magnetic coupling, effectively transitioning from a planar to a volumetric structure.
2Productivity
If transformers are manufactured on dies of integrated circuits, then the manufacturing process is established, but the process is costly and time-consuming
Solution Approach 1:
The patent makes the PCB serve multiple functions: it acts as both the circuit board substrate and the transformer structure. The standard PCB manufacturing process is used to create both the circuit traces and the transformer windings simultaneously, eliminating the need for separate IC die manufacturing processes and reducing both cost and time while maintaining compatibility with existing PCB production lines.
3Area of stationary object
If standard PCB techniques are used to create miniature transformers, then manufacturing cost and space are reduced, but the transformers must be suitable for high voltage applications
Solution Approach 1:
The patent applies different material properties and structural characteristics to different regions of the transformer to meet high voltage requirements. Insulating layers are strategically placed between windings and around high voltage areas, conductive vias are properly plated and isolated, and the magnetic core material is selected for high voltage insulation properties, ensuring that each local region has the appropriate quality for its specific electrical stress conditions.
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
Enables the creation of compact, cost-effective miniature transformers suitable for high voltage applications by utilizing standard PCB techniques, reducing space and manufacturing costs.
Implementation Method 1
Transformers are used to transfer energy by inductive coupling between two sets of windings of the transformer
Implementation Method 2
a ferrite core disposed inside a cavity in a printed circuit board (PCB) layer
Data Source
AI summary
An inductive device may include a pair of half-shell magnetically-conductive housings joined together and defining an enclosed cavity between them. The inductive device may also include primary and secondary windings provided spatially within the cavity providing magnetic coupling between them. The windings may be electrically insulated from each other and terminals of the primary and secondary windings may traverse to an exterior of the inductive device.