Segmented Winding Center-Tap Planar Transformer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing DC-DC switching regulators face design challenges in stepping down high supply voltages to low voltages and vice versa, leading to complexity and voltage stress across output inductors, which can be mitigated by employing segmented windings in planar transformers.
Innovation Solution
A multiple-layer planar transformer with center taps on a segmented winding, where each segment forms a fraction of a turn, allowing for reduced complexity, higher switching frequencies, and the use of air-core inductors, which reduces ripple current and simplifies the design by using fewer switches and lower inductance output inductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional windings are used in planar transformers, then the transformer can handle high supply voltages, but the design complexity increases and voltage stress across output inductors increases
Solution Approach 1:
The patent applies segmentation by dividing the secondary winding into multiple discrete segments (e.g., four segments) instead of using a conventional continuous winding. Each segment is independently connected to the core, allowing the voltage stress to be distributed across multiple points rather than concentrated across a single continuous winding. This segmentation reduces the voltage stress across each individual segment and the output inductors while maintaining the transformer's ability to handle high supply voltages.
2Speed
If conventional windings are used in planar transformers, then the transformer can step down high supply voltages, but the switching frequency is limited and the design requires more switches
Solution Approach 1:
The segmentation of the secondary winding into multiple segments enables higher switching frequencies by allowing each segment to be independently controlled and switched. This segmentation reduces the overall switching frequency requirements for the entire transformer while enabling faster individual segment switching. The segmented structure allows for more flexible switching schemes that can achieve higher effective switching frequencies without requiring a proportional increase in the number of switches.
Solution Approach 2:
The segmented winding structure provides multi-functionality by enabling the same transformer design to operate in multiple modes (step-down, step-up, isolated, non-isolated) without requiring different numbers of switches. The segmented architecture allows a single set of switches to control multiple segments, providing universal operation across different voltage conversion scenarios while maintaining a consistent switch count.
3Weight of moving object
If conventional windings are used in planar transformers, then the transformer can provide the required inductance, but the size and weight increase
Solution Approach 1:
The segmented winding structure allows for the use of air-core inductors or simplified core structures because the magnetic flux is distributed across multiple segments rather than requiring a single large continuous core. Each segment can be paired with smaller, lighter core structures or air cores, significantly reducing the overall transformer weight and size while maintaining the required inductance through the combined effect of all segments.
4Ease of manufacture
If conventional windings are used in planar transformers, then the transformer can handle high voltages, but the manufacturing cost increases
Solution Approach 1:
The segmented winding structure simplifies manufacturing by allowing each segment to be independently fabricated and assembled, reducing the complexity of handling high voltages during the manufacturing process. The segmentation allows for lower voltage stress during assembly and testing of individual segments, making the manufacturing process safer and less expensive. The modular segmented structure also allows for easier repair and replacement of individual segments without requiring complete transformer disassembly.
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 results in a more compact, cost-effective, and efficient DC-DC converter design with reduced voltage stress and ripple current, enabling the use of air-core inductors for smaller, lighter, and less expensive transformer solutions.
Implementation Method 1
a first winding (106) including a plurality of turns and configured to receive an input voltage, a second winding (107, 108) configured to magnetically couple with the first winding (106)
Data Source
AI summary
Techniques are provided for a multiple-layer planar transformer having center taps of a segmented winding. In an example, a multiple-layer planar transformer can be a coupled inductor circuit including a first winding comprising a conductive coil having an electrical path defining and encircling the central axis, a second winding configured to magnetically couple with the first winding, the second winding having a plurality of individual segments, wherein each individual segment forms a fraction of one turn of the second winding, and a first output inductor coupled to a first common node of the second winding. The first common node can directly couple a first node of a first individual segment of the plurality of individual segments with a first node of a second individual segment of the plurality of individual segments.