Low-Profile Magnetic Component with Planar Winding and Segmented Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Magnetic components, such as transformers, face challenges in reducing size and cost while maintaining electrical performance, particularly in space-constrained applications where traditional designs are inefficient and costly.
Innovation Solution
A magnetic component design featuring a pair of core halves with a center leg and outer legs, inserted into a hollow bobbin, allows for a low-profile transformer structure with a large winding area, reducing leakage inductance and enabling better cooling, and includes a method for winding conductors around the bobbin to minimize height and maximize surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional copper wire is wound around ferrite cores, then electrical performance is achieved, but the component size and height are large
Solution Approach 1:
The patent transitions from traditional three-dimensional wire winding around cores to a planar two-dimensional configuration where copper traces are etched on flat dielectric substrates that are stacked on flat ferrite cores. This dimensional change allows the magnetic component to achieve its electrical performance in a planar format, significantly reducing height and enabling surface mounting while maintaining functionality.
Solution Approach 2:
The magnetic core is divided into two separate E-shaped core halves that are positioned on opposite sides of the planar winding structure. This segmentation allows the core to be inserted into a bobbin assembly in a simplified manner and enables the planar configuration to achieve the desired magnetic circuit while maintaining a low-profile structure suitable for surface mounting.
2Volume of moving object
If planar transformers with copper lead frames and etched spirals are used, then size is reduced, but manufacturing cost and efficiency decrease
Solution Approach 1:
The patent combines the advantages of traditional wire-wound transformers with planar technology by using a hybrid construction. The copper traces are etched on dielectric substrates that are then stacked and secured within a bobbin assembly that also contains traditional E-shaped ferrite core halves. This merging approach maintains manufacturing simplicity and cost-effectiveness while achieving the size reduction benefits of planar design.
3Length of stationary object
If component height is reduced for space-constrained applications, then mounting on PCB is enabled, but winding area and cooling capability are limited
Solution Approach 1:
The patent resolves this contradiction by expanding the winding area in the planar (horizontal) dimension rather than increasing height. Multiple dielectric substrates with copper traces are stacked side-by-side in a planar configuration within the bobbin, providing a large total winding area while maintaining a low profile that enables surface mounting on PCBs.
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 a low-profile, efficient, and cost-effective magnetic component with reduced leakage inductance and improved cooling, suitable for space-constrained applications like power adapters and portable devices.
Implementation Method 1
Transformers generally operate on the principle that a change in current flowing through a first winding conductor, which is isolated from a second winding conductor, creates a magnetic flux that causes a change in the current flow in the second winding conductor.
Implementation Method 2
To form the magnetic field in the transformer, a core assembly having high magnetic permeability may be inserted into the bobbin.
Data Source
AI summary
Generally, methods and processes for assembling magnetic components are presented herein. More specifically, conductors are wound around a substantially hollow bobbin. Portions of the conductors may be temporarily positioned outside the bobbin through slots in the flanges of the bobbin during the assembly process. Insulating layers may be wrapped around the conductors. The center legs of a pair of magnetic core halves may be inserted into the bobbin. The base of the magnetic core halves may have a passage to allow a conductor to pass therethrough at a height less than the height of the base.