Planar Transformer Insulating Structure for Compact PCB Isolation
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Solution Overview
Problem
Conventional transformers face challenges in miniaturization due to the need for maintaining an insulation distance between the primary and secondary parts, which results in increased size and resistance, limiting their efficiency and compactness.
Innovation Solution
A planar transformer design incorporating an insulating structure with a pair of ferrite cores, a printed circuit board, and an insulating block and base that ensures an insulation distance without extending the coil patterns, allowing for miniaturization and enhanced coupling force among components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation distance between primary and secondary parts is maintained by increasing the transformer size, then electrical stability is improved, but miniaturization is hindered
Solution Approach 1:
An insulating block is introduced as an intermediary component between the primary and secondary parts. This insulating block includes an insulating base and an insulating block body that protrudes from the insulating base, creating a physical barrier that ensures the insulation distance without requiring the entire transformer to be larger. The insulating block mediates the spatial relationship between primary and secondary components while maintaining compact overall dimensions.
Solution Approach 2:
The insulating block body protrudes in a direction extending from the insulating base, utilizing the vertical dimension (thickness direction) to provide insulation distance. This dimensional approach allows the insulation function to be achieved without increasing the planar area of the transformer, thereby enabling miniaturization while maintaining electrical stability.
2Reliability
If the lengths of coil patterns on the printed circuit board are increased to ensure insulation distance, then electrical stability is improved, but resistance increases
Solution Approach 1:
The insulating block serves as a mediator that provides the necessary insulation distance without requiring longer coil patterns. By placing the insulating block between primary and secondary parts, the patent achieves electrical stability through spatial separation rather than through extended trace lengths, thereby avoiding increased resistance.
3Reliability
If the insulation distance is maintained by increasing the planar area of the transformer, then electrical stability is improved, but miniaturization is hindered
Solution Approach 1:
The insulating block body protrudes in the thickness direction from the insulating base, utilizing the vertical dimension to provide insulation distance. This approach shifts the insulation function from the planar area dimension to the thickness dimension, allowing the transformer to maintain a compact planar footprint while ensuring adequate insulation distance for electrical stability.
Solution Approach 2:
The insulating structure is segmented into two distinct parts: an insulating base that provides a foundation, and an insulating block body that protrudes to create the insulation distance. This segmentation allows the insulation function to be achieved in the vertical direction without increasing the horizontal area of the transformer.
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
The design achieves miniaturization of the transformer while maintaining electrical stability, reducing resistance, and minimizing the size of the printed circuit board, thereby enhancing efficiency and reducing manufacturing costs.
Implementation Method 1
the transformer includes primary winding to which the commercial voltage is applied and secondary winding from which a lower voltage than the commercial voltage is outputted. If the alternating current voltage flows to the primary winding, the alternating current voltage inducedly flows to the secondary winding
Implementation Method 2
an insulating block for accommodating one side of the pair of ferrite cores; and an insulating base disposed at the inside of the pair of ferrite cores in such a manner as to be fitted to the insulating block
Data Source
AI summary
A planar transformer employing an insulating structure for performance improvement includes: a pair of ferrite cores (110) including an upper core (110-1) and a lower core (110-2); a printed circuit board (120), which is disposed between the pair of ferrite cores (110), one end of which has primary via holes (121) electrically connecting primary coil patterns, and the other end of which has secondary via holes (123) electrically connecting secondary coil patterns; an insulating block (130-1) for receiving one side of the pair of ferrite cores (110); and an insulating base (130-2) disposed in the pair of ferrite cores (110) and fittedly coupled to the insulating block (130-1), wherein the insulating block (130-1) and the insulating base (130-2) receive a given region of the printed circuit board (120) at one side at which the secondary via holes (123) is disposed.