Split Core Isolated Power for Aircraft Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional lighting systems in aircraft require bulky inductors and transformers, increasing height and weight, and necessitating connectors that add complexity and size, while also lacking electrical isolation.
Innovation Solution
The magnetic core of inductors and transformers is split, with one half embedded in the power module and the other in the circuit module, eliminating the need for connectors and allowing the entire assembly to be encased in a waterproof housing, reducing size and weight while enhancing isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inductors and transformers are used in lighting systems, then electrical isolation is provided, but the height, weight, and size increase significantly
Solution Approach 1:
The magnetic core is divided into two separate halves, each embedded in different circuit boards. This segmentation allows the magnetic flux to bridge across the air gap between boards, providing electrical isolation while reducing the overall height and weight of the assembly compared to a single bulky transformer component.
2Reliability
If traditional inductors and transformers are used in lighting systems, then electrical isolation is provided, but the overall size and height increase
Solution Approach 1:
The magnetic flux path transitions from a vertical through-core path in a traditional transformer to a horizontal path across an air gap between two circuit boards. This dimensional change allows the magnetic coupling to occur in the planar direction rather than requiring significant height, thereby reducing the overall assembly height while maintaining electrical isolation.
3Ease of operation
If connectors are used to couple power module and circuit module, then electrical connection is established, but complexity and size increase
Solution Approach 1:
The magnetic core halves are embedded directly into the circuit boards, merging the inductor/transformer function with the circuit board structure. This eliminates the need for separate connectors and wiring harnesses, reducing both complexity and size while maintaining reliable electrical connection through the magnetic flux path.
4Reliability
If traditional transformer design is used, then power isolation is achieved, but weight and size increase
Solution Approach 1:
The transformer is segmented into two halves mounted on separate circuit boards with an air gap between them. This segmentation reduces the amount of magnetic core material required while maintaining the isolation function through the air gap magnetic flux path, thereby reducing the overall weight of the power supply system.
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 solution reduces the size and weight of lighting assemblies, enhances reliability and isolation, and allows for a more compact, sealed, and efficient power supply system.
Implementation Method 1
a magnetic flux generated in the first half magnetic core is passed to the second half magnetic core
Implementation Method 2
A second electric current is generated in the first set of windings due to the magnetic flux
Data Source
AI summary
A lighting unit is provided. The lighting unit includes a first circuit board, a second circuit board, a light array mounted on the first circuit board, and a controller mounted on the first circuit board and coupled to the light array. The light unit further includes a first portion of an isolated power supply system mounted on the first circuit board and coupled to the controller and a second portion of the isolated power supply system mounted on the second circuit board. The first portion includes a first half magnetic core and a first set of windings and the second portion includes a second half magnetic core and a second set of windings. The first circuit board is coupled to the second circuit board so that a magnetic flux generated in the first half magnetic core is passed to the second half magnetic core.