Planar Transformer Pillar Layout for Thinner Core Covers
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Solution Overview
Problem
Conventional planar transformers are not thin enough to meet the requirements of ultra-thin product designs, particularly in miniaturized and ultra-thin electronic devices, due to their volume and height constraints.
Innovation Solution
A planar transformer design that incorporates a magnetic core with auxiliary inductor windings on secondary magnetic core pillars, which generate a magnetic flux that cancels part of the primary-side winding flux, allowing for a thinner magnetic core cover and reduced magnetic flux through the core, achieved by optimizing the cross-sectional area ratio and turn ratio of the windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional planar transformer structure is used, then magnetic flux is efficiently transferred, but the transformer thickness cannot be reduced further to meet ultra-thin product requirements
Solution Approach 1:
The magnetic core is segmented into multiple pillars (first magnetic core pillars and second magnetic core pillars) with different functions. The first pillars handle primary magnetic flux while the second pillars generate counteracting magnetic flux, allowing independent optimization of each segment's role in flux management
Solution Approach 2:
The auxiliary inductor windings on the second magnetic core pillars generate a magnetic flux that preliminarily counteracts the magnetic flux from the primary-side windings. This preliminary anti-action reduces the net magnetic flux passing through the magnetic core cover, enabling thinner design while maintaining efficiency
2Length of moving object
If magnetic core cover thickness is reduced for ultra-thin design, then product thinness is achieved, but magnetic flux cancellation effect is insufficient
Solution Approach 1:
The patent optimizes key parameters including the cross-sectional area ratio between first and second magnetic core pillars, the turn ratio of primary-side to auxiliary inductor windings, and the positioning of pillars within the magnetic core cover. These parameter changes maximize magnetic flux cancellation while enabling ultra-thin design
3Object-generated harmful factors
If auxiliary inductor windings are added on second magnetic core pillars, then magnetic flux is reduced through cancellation, but device structure becomes more complex
Solution Approach 1:
The auxiliary inductor windings are merged with the magnetic core structure by winding them around the second magnetic core pillars, which are integrated into the same magnetic core cover as the primary-side windings. This merging approach adds flux cancellation functionality without requiring separate external components
Solution Approach 2:
The second magnetic core pillars serve dual functions: providing structural support within the magnetic core assembly and serving as carriers for auxiliary inductor windings that generate counteracting magnetic flux. This multi-functionality reduces the need for additional separate components
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 results in a thinner magnetic core cover with reduced magnetic flux, enabling the creation of ultra-thin products while maintaining efficient magnetic induction and minimizing winding losses.
Implementation Method 1
a first magnetic flux cancels a part of a second magnetic flux when passing through the first magnetic core cover and the second magnetic core cover, the first magnetic flux is a magnetic flux generated by auxiliary inductor windings disposed on the k second magnetic core pillars, and the second magnetic flux is a magnetic flux generated by primary-side windings disposed on the n first magnetic core pillars
Data Source
AI summary
A planar transformer includes a magnetic core. The magnetic core includes a first magnetic core cover, a second magnetic core cover, n first magnetic core pillars, and k second magnetic core pillars, the n first magnetic core pillars and the k second magnetic core pillars are disposed between the first magnetic core cover and the second magnetic core cover, and n and k each are an integer greater than 0. A primary-side winding and a secondary-side winding that are coupled to each other are disposed on each of the n first magnetic core pillars, and an auxiliary inductor winding is disposed on each of the k second magnetic core pillars.