Planar Transformer Design for Miniaturization and Safety
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Solution Overview
Problem
Existing transformer designs face challenges in miniaturization and simplified manufacturing due to the need for complex creepage distances and uniform winding configurations, which complicate the manufacturing process and increase size.
Innovation Solution
A transformer design featuring a magnetic core with a laminated board structure, including first and second coil units with conductive patterns and insulating distances secured by insulating layers or sheets, and a conductive wire surrounded by insulating paper, to reduce leakage inductance and secure safety standards while minimizing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional transformer structure with separate windings and core is used, then safety requirements can be met, but the size occupies nearly one-third of the power source unit volume
Solution Approach 1:
The patent merges the primary and secondary windings into a single planar coil structure fabricated on the same substrate, eliminating the need for separate winding components and their associated insulation structures. This integration dramatically reduces the overall transformer volume while maintaining electrical isolation through the insulating substrate layer.
Solution Approach 2:
The patent transitions from traditional three-dimensional cylindrical windings to a two-dimensional planar coil structure fabricated on a substrate. This dimensional change allows for more compact packaging and better integration with surface-mounted power source units, reducing the vertical height and overall volume occupation.
2Reliability
If creepage distance requirements are enforced between windings and core, then safety standards are satisfied, but the manufacturing process becomes complicated
Solution Approach 1:
The insulating substrate structure automatically provides the required creepage distance between the planar coil and the magnetic core through its inherent thickness and material properties. This self-provided insulation eliminates the need for additional insulating tapes, complex spacing structures, or manual insulation verification processes, thereby simplifying manufacturing while ensuring safety compliance.
3Ease of operation
If manual winding of coils is performed, then flexibility in assembly is maintained, but winding positions and turns become non-uniform
Solution Approach 1:
The patent replaces the mechanical manual winding process with a planar printed circuit board fabrication process. The coil traces are formed through standard PCB techniques such as copper plating and etching, which provide precise control over winding positions, turns, and geometries. This substitution eliminates human variability while maintaining ease of assembly through standardized manufacturing processes.
4Reliability
If insulating tapes are wound on primary and secondary coils, then safety requirements are met, but the manufacturing process is complicated
Solution Approach 1:
The patent combines the insulation function with the structural substrate itself. The insulating substrate serves dual purposes: as the mechanical support for the planar coil and as the electrical insulation barrier between the coil and the magnetic core. This eliminates the need for separate insulating tape applications, reducing manufacturing steps and potential defects.
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 transformers by ensuring insulating distances and reducing leakage inductance, simplifying the manufacturing process and meeting safety standards, thereby reducing size and manufacturing complexity.
Implementation Method 1
The insulating distance is secured by an insulating layer coupled to at least one of the first coil unit and the second coil unit
Implementation Method 2
A transformer may include a magnetic core, a first coil unit and a second coil unit
Implementation Method 3
The first coil unit is disposed within the magnetic core
Implementation Method 4
a laminated board having a plurality of first layers laminated therein. Respective conductive patterns are disposed on the first layers
Implementation Method 5
The conductive wire may be surrounded by at least two sheets of insulating paper
Data Source
AI summary
A transformer includes a magnetic core, a first coil unit and a second coil unit. The first coil unit is disposed within the magnetic core and includes a laminated board having layers laminated therein and conductive patterns. Respective ones of the conductive patterns are disposed on the laminated layers. The second coil unit includes a conductive wire spaced apart from the conductive patterns of the laminated board by an insulating distance. The conductive wire includes a triple-insulated wire surrounded by three sheets of insulating paper to maintain the insulating distance from the conductive patterns.