Laminated Transformer Layout for Thin, High-Coupling Coils
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Solution Overview
Problem
Traditional ferrite transformers are bulky due to their thickness and have high thermal resistance, and laminated transformers with low coupling coefficients fail to achieve desired characteristics for miniaturization and performance.
Innovation Solution
A laminated transformer structure is developed, comprising multiple magnetic and non-magnetic layers, where non-magnetic layers are strategically placed between coil layers to increase the coupling coefficient, and a manufacturing method involving casting, screen printing, and lamination is used to reduce thickness and enhance thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional ferrite lamination process is used to achieve small volume, then volume is reduced, but thermal resistance increases and coupling coefficient decreases
Solution Approach 1:
The transformer core is divided into multiple thin ferrite layers (e.g., 0.1mm thickness) stacked together, with each layer separated by insulating films. This segmentation allows the magnetic flux to be guided through controlled paths while maintaining small overall volume and improving coupling between windings.
Solution Approach 2:
Insulating films are introduced as intermediary layers between adjacent ferrite layers and between the ferrite core and copper windings. These intermediaries prevent eddy current losses while maintaining magnetic coupling, thereby improving the coupling coefficient without increasing volume.
2Volume of moving object
If traditional ferrite lamination process is used to achieve small volume, then volume is reduced, but thermal resistance increases
Solution Approach 1:
Thin insulating films are used to separate ferrite layers, providing electrical isolation to reduce eddy currents while maintaining thermal conduction paths. The thin film structure minimizes thermal resistance accumulation across layers while preventing harmful eddy current losses.
3Reliability
If multi-layer technology is used for transformers, then coupling coefficient can be improved, but manufacturing complexity increases
Solution Approach 1:
Multiple ferrite layers are combined into a single integrated core structure with windings positioned between specific layers. This merging approach achieves high coupling coefficients through the layered construction while simplifying manufacturing by treating the multi-layer assembly as one unified component rather than separate parts.
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 more compact transformer with improved thermal performance and increased coupling coefficient, effectively addressing the bulkiness and thermal resistance issues of traditional transformers.
Implementation Method 1
a first of the plurality of non-magnetic layers is disposed between an adjacent pair of the coil layers in order to increase a coupling coefficient between the primary and secondary coils
Data Source
AI summary
A laminated transformer can include: a plurality of magnetic layers; a plurality of coil layers including a primary coil having a first type of coil layer, and a secondary coil having a second type of coil layer, where each coil layer is laminated between a pair of the plurality of magnetic layers; and a plurality of non-magnetic layers, where a first of the plurality of non-magnetic layers is disposed between an adjacent pair of the coil layers in order to increase a coupling coefficient between the primary and secondary coils.