Multilayer Transformer Coil Alignment for Voltage Stability
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Solution Overview
Problem
Conventional transformers with multilayer boards experience output voltage drops and reduced power conversion efficiency due to non-uniform coupling coefficients between primary and secondary coils, caused by inconsistent coil alignments and clearances.
Innovation Solution
The transformer design aligns the average positions of primary and secondary sub-coils on different layer planes of the multilayer board, ensuring uniform coupling coefficients by electrically connecting sub-coils in series and arranging them to face each other at specific positions, thereby maintaining consistent magnetic flux distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multilayer board transformers are constructed with stacked base materials and coils, then the transformer structure is formed, but non-uniform coupling coefficients occur between primary and secondary coils due to inconsistent alignments and clearances
Solution Approach 1:
The primary coil is divided into multiple first subcoils and the secondary coil into multiple second subcoils. Each subcoil is positioned on different layer planes of the multilayer board, allowing independent placement optimization. This segmentation enables uniform coupling coefficients between corresponding subcoils while maintaining overall coil functionality, directly resolving the alignment uniformity issue.
Solution Approach 2:
The invention utilizes the thickness direction (z-axis) of the multilayer board by placing subcoils on multiple different layer planes. Instead of arranging all subcoils on the same plane, the patent distributes them across multiple layers with corresponding subcoils facing each other through the insulation layers. This dimensional approach ensures consistent clearances and coupling coefficients, preventing output voltage drops.
2Reliability
If coils are placed on multiple layer planes, then uniform coupling coefficients can be achieved, but the transformer structure becomes more complex
Solution Approach 1:
The multilayer board serves multiple functions simultaneously: it provides electrical insulation between primary and secondary coils, structures the magnetic coupling paths through its layered architecture, and positions the subcoils with precise clearances. The insulation layers act as both electrical barriers and magnetic flux guides, reducing the need for separate structural components and simplifying the overall design despite the multilayer configuration.
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 output voltage drops and maintains uniform power conversion efficiency, reducing noise and minimizing the transformer's size and cost by optimizing coil placement and alignment.
Implementation Method 1
a primary coil provided on at least one of the insulation layers of the multilayer board, and a secondary coil provided on at least one of the insulation layers of the multilayer board
Data Source
Figure 1A~1B
Figure 2A~2D
Figure 3A~3D
AI summary
A transformer includes a multilayer board including insulation layers stacked in a thickness direction, a primary coil provided on at least one of the insulation layers, and a secondary coil provided on at least one of the insulation layers. The primary coil includes first sub coils electrically connected in series to each other, and second sub coils electrically connected in series to each other. Surfaces of the plurality of insulation layers constitute layer planes of the multilayer board. At least two of the first sub coils are provided on layer planes out of the layer plane different from each other. At least two of the second sub coils are provided on layer planes out of the layer planes different from each other. An average of positions of the first sub coils in the thickness direction is aligned with an average of positions of the second sub coils in the thickness direction.