Planar Transformer Galvanic Isolation via Segmented Windings
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Solution Overview
Problem
Existing planar transformers face challenges in miniaturization while maintaining galvanic isolation and intrinsically safe operations, particularly in accommodating additional circuits without compromising safety standards, especially when circuits are stacked vertically.
Innovation Solution
The design incorporates a layered arrangement of circuits within the same plane, allowing for additional galvanically isolated circuits to be integrated above or below existing ones, with minimal height increase, using a combination of printed circuit boards and modular core structures to ensure intrinsically safe galvanic isolation, and utilizing center taps and multiple cores for expanded geometry and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional circuits are integrated into the planar transformer, then the functionality and circuit capacity are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The planar transformer is divided into multiple independent circuit units, each with its own winding and core structure. These segmented circuits are arranged in a modular fashion on the planar substrate, allowing independent design and manufacturing of each unit while maintaining overall system functionality.
Solution Approach 2:
Multiple circuit windings are nested within the same planar structure by utilizing different layers or regions of the planar substrate. The windings are arranged concentrically or in overlapping patterns that allow multiple circuits to share the same physical space without interfering with each other's magnetic fields.
2Area of stationary object
If circuits are arranged vertically one above another to save space, then the area utilization is improved, but the galvanic isolation and intrinsically safe operation may be compromised
Solution Approach 1:
Instead of arranging circuits vertically in the third dimension, the invention utilizes the two-dimensional planar substrate to arrange circuits side-by-side in different regions. This dimensional approach allows maintaining adequate separation distances for galvanic isolation while achieving high area utilization through optimized planar layout patterns.
Solution Approach 2:
Different regions of the planar transformer are designed with locally optimized properties - some regions have dense winding patterns for high circuit capacity, while other regions maintain larger separation distances for galvanic isolation. The magnetic core structure is also locally optimized to confine magnetic fields to specific regions, preventing interference between adjacent circuits.
3Volume of moving object
If the transformer is designed with compact dimensions for miniaturization, then the volume and space requirement are reduced, but the separation distances for intrinsically safe operation may be insufficient
Solution Approach 1:
The planar transformer utilizes composite magnetic core structures with high permeability materials to concentrate and confine magnetic flux within small regions. This allows the magnetic coupling between windings to be effective even at reduced separation distances, enabling miniaturization while maintaining intrinsically safe operation parameters.
Solution Approach 2:
The invention optimizes key parameters including winding turn ratios, wire diameters, and core permeability to achieve effective magnetic coupling at compact dimensions. By carefully adjusting these parameters, the transformer maintains required separation distances for intrinsically safe operation while minimizing overall volume through optimized geometric proportions.
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 approach enables more circuits to be galvanically isolated within the same space without compromising safety, ensuring compliance with intrinsically safe standards by maintaining separation distances and avoiding interference, while allowing for cost-effective production and modular expansion.
Implementation Method 1
Planar transformers are transformers in which individual windings of the transformer are arranged next to one another essentially in one plane
Implementation Method 2
both energy and signals and/or data can be transmitted via the transformer
Data Source
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AI summary
The invention relates to a planar transmitter (30) having a vertical extent and a horizontal extent, having a layer structure with a plurality of electrical circuits (1, 2, 3), wherein a first electrical circuit (1) and a second electrical circuit (2) are electrically conductively disconnected from one another. The transmitter also has at least one magnetic core (4) which at least partially surrounds the layer structure and acts at least on the first electrical circuit (1) and on the second electrical circuit (2), wherein the first electrical circuit (1) and the second electrical circuit (2) lie substantially in one plane and form one layer of the layer structure. Provision is further made for at least the first electrical circuit (1) or the second electrical circuit (2) to be subdivided into a plurality of electrical circuits (1, 1a, 2, 2a) which are electrically conductively disconnected from one another.