Power Supply Transformer Coil Minimizing AC Loop Length
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Solution Overview
Problem
Existing power supply units face efficiency losses due to increased resistance in copper foil patterns on miniaturized circuit boards, leading to heat generation and potential burnout, and the addition of conductors to mitigate this increases costs and part count, while also causing losses due to the skin effect.
Innovation Solution
A power supply device with a transformer that includes a secondary coil with a conductive metal base and terminal portions connected to substrates, allowing direct current to be output without the need for additional conductors, thereby reducing heat generation and part count, and minimizing the alternating current loop length to prevent efficiency decreases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If copper foil patterns are used on miniaturized circuit boards, then circuit board size is reduced, but resistance increases causing heat generation and potential burnout
Solution Approach 1:
The patent divides the current path into multiple segments by introducing external conductors that connect to intermediate connection portions on the circuit board. This segments the current flow to bypass high-resistance copper foil patterns, reducing overall resistance loss while maintaining miniaturized board size.
Solution Approach 2:
The patent introduces intermediate connection portions as mediators between the copper foil patterns and external conductors. These connection portions serve as transition points that enable low-resistance current paths while maintaining the miniaturized circuit board structure.
2Loss of energy
If additional conductors are added to mitigate resistance loss, then heat generation is reduced, but device complexity and part count increase
Solution Approach 1:
The patent merges the function of additional conductors with the existing circuit board structure by integrating connection portions directly into the board. This combines multiple functions (current conduction, structural support, electrical connection) into unified components, reducing part count while mitigating heat generation.
3Loss of energy
If additional conductors are added to reduce resistance loss, then heat generation decreases, but manufacturing cost increases
Solution Approach 1:
The patent combines the conductor function with the circuit board structure itself, eliminating the need for separate additional conductor components. This integration reduces assembly steps and part procurement costs while effectively reducing heat generation through lower resistance paths.
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 configuration prevents efficiency decreases in power supply units by reducing heat generation and part count, improving manufacturability and flexibility in circuit design while avoiding losses associated with the skin effect.
Implementation Method 1
a coil portion that includes a base that includes a conductive metal, a first terminal portion connected to a circuit board on which a rectifier circuit is mounted, and a second terminal portion that outputs a direct current rectified by the rectifier circuit
Data Source
AI summary
An electronic component including: a coil portion that includes a base that includes a conductive metal, a first terminal portion connected to a circuit board on which a rectifier circuit is mounted, and a second terminal portion that outputs a direct current rectified by the rectifier circuit.