Surface-Mounted Transformer Structure for Crack-Resistant Miniaturization

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Solution Overview

Problem

Traditional auxiliary power transformers, such as winding transformers, face challenges in adapting to plastic package environments due to magnetic core assembly structure limitations, leading to cracking and performance deterioration, and are also large in size, making miniaturization difficult.

Innovation Solution

A surface-mounted transformer with an adhesive layer and a winding product, featuring an I-shaped magnetic core and a coil wound on its middle pillar, where the coil's leading-out ends are connected to electrodes exposed on the adhesive layer, which is formed through compression molding of a magnetic molding material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional winding transformer structure is used, then magnetic core assembly is simple, but cracking occurs under plastic package and temperature changes

Engineering Contradiction:

Improveresistance to crackingVSAvoidmagnetic core assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses a composite magnetic core structure combining ferrite magnetic powder with a resin matrix, creating a flexible composite material that can withstand thermal expansion and contraction without cracking. This composite approach allows the magnetic core to maintain structural integrity under plastic package constraints and repeated temperature changes.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the physical and chemical parameters of the magnetic core material by using a flexible resin-based composite instead of traditional rigid ferrite. This parameter change enables the magnetic core to adapt to thermal stress and mechanical constraints, preventing cracking while maintaining magnetic performance.

Inventive Principle:

Principle #35Parameter changes

2Volume of moving object

If traditional winding transformer is used, then magnetic core structure is conventional, but size is large and miniaturization is difficult

Engineering Contradiction:

Improvetransformer sizeVSAvoidminiaturization capability

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent merges the magnetic core, insulation, and structural support functions into a single integrated flexible composite magnetic core component. This consolidation eliminates the need for separate bobbin, insulation layers, and structural supports, enabling significant size reduction while maintaining functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a flexible resin-based magnetic core that can be formed into thin, compact structures. The flexibility of the composite material allows for miniaturized designs that would be impossible with traditional rigid magnetic cores, enabling the transformer to fit into smaller electronic devices.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If traditional winding transformer is used, then structure is conventional, but cannot adapt to plastic package environment

Engineering Contradiction:

Improvecompatibility with plastic packageVSAvoidelectric performance stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent changes the thermal and mechanical parameters of the magnetic core by using a resin-based composite with flexible properties. This allows the magnetic core to expand and contract with the plastic package during temperature cycles, preventing delamination and maintaining electrical performance stability in the plastic package environment.

Inventive Principle:

Principle #35Parameter changes

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 solution results in a smaller transformer size with over 50% reduction in size compared to traditional transformers, improved reliability, and the ability to withstand repeated temperature changes without cracking, supporting high reflow soldering and machinability.

Implementation Method 1

the adhesive layer is obtained through compression molding forming of a magnetic molding material

Methodology Applied

Scientific EffectCompression molding: Compression

Implementation Method 2

welding and fixation by hot pressing

Methodology Applied

Scientific EffectHot pressing: Heating

Data Source

PatentUS12266467B2Surface-mounted transformer and processing method thereof

Publication Date: 2025.04.01 SHENZHEN SUNLORD ELECTRONICS

AI summary

A surface-mounted transformer includes an adhesive layer and a winding product. The winding product is disposed inside the adhesive layer; the winding product includes an I-shaped magnetic core and a coil wound on a middle pillar of the I-shaped magnetic core; leading-out ends of the coil are connected to electrodes; the electrodes are exposed on the surface of the adhesive layer; and the adhesive layer is obtained through compression molding forming of a magnetic molding material. Compared with a surface-mounted transformer in the prior art, which has equal performance indexes, the surface-mounted transformer has a smaller size with a decrease proportion of over 50%; and a BOBBIN and an insulating rubber tape do not need to be used in processing. The winding product in the surface-mounted transformer is completely covered by the adhesive layer, so that the product is high in reliability and can support a PSIP plastic package environment.