Planar Transformer PCB Winding Layout for Lower Loss and Coupling
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Solution Overview
Problem
Current planar magnetic components suffer from significant losses due to copper and iron losses, which are interdependent and affect overall performance, and there is a need to optimize their integration and reduce stray inductances and couplings.
Innovation Solution
A transformer design with a primary and secondary winding structure on multiple layers, interconnected via central vias, a vertical air gap, and a shielding plane, optimizing the layout to minimize losses and improve integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If planar magnetic components are designed with traditional winding structures, then manufacturing is simplified, but copper losses and iron losses increase significantly
Solution Approach 1:
The patent transitions from traditional planar windings to a three-dimensional vertical winding structure around central vias. The windings are arranged in multiple layers (first layer, second layer, third layer) stacked vertically, with each layer contributing to the magnetic field in a different spatial dimension. This vertical stacking allows better magnetic coupling and reduced losses while maintaining PCB integration.
Solution Approach 2:
The patent implements a nested structure where multiple winding layers are concentrically arranged around central vias. The first, second, and third layers are nested vertically, with each layer's winding path enclosing the central via structure. This nesting maximizes space utilization and magnetic field concentration, reducing both copper and iron losses.
2Adaptability or versatility
If multiple PCB layers are used for windings, then component integration is enhanced, but stray inductances increase
Solution Approach 1:
The patent applies local quality by positioning different winding layers at specific vertical positions around the central vias. Each layer (first, second, third layer) is assigned a specific height range, creating localized magnetic field zones. This spatial differentiation allows optimization of magnetic coupling in each zone while minimizing stray inductance through controlled current paths.
Solution Approach 2:
The patent uses the vertical dimension (Z-axis) to separate winding layers, with each layer positioned at a different height. This vertical stacking in the third dimension allows multiple windings to coexist without planar interference, reducing stray inductance while maintaining high PCB integration. The central vias serve as the common axis for all layers, organizing the three-dimensional structure.
3Ease of manufacture
If windings are arranged in a single plane, then manufacturing is easier, but magnetic coupling between primary and secondary circuits is reduced
Solution Approach 1:
The patent implements nested concentric windings around central vias, with primary and secondary windings interleaved in a nested configuration. The first, second, and third layers contain alternating primary and secondary windings that are concentric with the same central via axis. This nested arrangement maximizes magnetic coupling by ensuring that primary and secondary current paths are closely intertwined in three-dimensional space.
Solution Approach 2:
The patent transitions from planar to vertical arrangement, with windings distributed across multiple vertical layers. The primary and secondary windings are separated in the vertical dimension rather than being coplanar, allowing enhanced magnetic coupling through three-dimensional interleaving. Each layer contributes to the overall coupling, with the vertical stacking creating multiple coupling zones.
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 reduces copper and iron losses, enhances integration, and improves performance by minimizing stray inductances and couplings, particularly in high-frequency applications.
Implementation Method 1
The component 5 comprises a ferromagnetic core 8, which makes it possible to channel the magnetic field.
Implementation Method 2
The circulation of the current in the electrical circuit generates losses in the same way as the circulation of the magnetic field in the magnetic circuit.
Data Source
AI summary
An innovative planar transformer structure, the transformer includes a primary circuit comprising a primary winding of N1 turns; a secondary circuit comprising a secondary winding of N2 turns; a printed circuit board of layers superposed on one another, forming an aperture defining a perimeter; vias disposed at the centre of the primary and secondary windings on the perimeter of the aperture, the N1 and N2 turns being each disposed on a layer, according to any alternation between the N1 and N2 turns, each of the N1 and N2 turns being wound, partially around vias in forming a circular arc per layer; the circular arc of a layer being distinctly oriented with respect to the circular arcs of the other layers.