Transformer With Optimized Core Diameter For Low Profile
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Solution Overview
Problem
Traditional transformers have large form factors and high magnetic and copper losses, especially at high frequencies, due to the need for extensive winding space and core material, which increases the number of parts and connections required, leading to inefficiencies and space constraints in devices.
Innovation Solution
A transformer assembly with a magnetic core and windings optimized for low profile and high efficiency, featuring a single or two turns of primary conductive material and multiple turns of secondary conductive material, where the core diameter is sized to achieve inductance with core losses comparable to winding losses, reducing leakage and proximity effect losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional transformers use extensive winding space and core material to achieve sufficient inductance, then inductance requirement is met, but form factor becomes large and magnetic losses increase
Solution Approach 1:
The patent changes the physical parameters of the magnetic core, specifically using a high permeability core material and optimizing the core cross-sectional area to be substantially equal to the winding area. This parameter optimization allows achieving sufficient inductance with minimal windings (1-2 turns), dramatically reducing both magnetic losses and the large winding area required by traditional transformers
2Loss of energy
If traditional transformers use large number of windings to achieve sufficient inductance, then inductance requirement is met, but copper losses increase
Solution Approach 1:
The patent optimizes the magnetic core parameters (high permeability, optimized cross-sectional area) to maximize magnetic coupling efficiency. This allows the transformer to achieve sufficient inductance with only 1-2 turns of primary and secondary windings, reducing copper losses and simplifying the winding structure compared to traditional multi-turn designs
3Productivity
If traditional transformers operate at high frequencies, then power processing capability is improved, but proximity effect losses become very large
Solution Approach 1:
The patent uses a high permeability magnetic core material with optimized geometry that maintains effective magnetic coupling at high frequencies. The core cross-sectional area is specifically optimized to work with minimal windings (1-2 turns), reducing the proximity effect between adjacent windings and allowing high-frequency operation with minimal proximity effect losses
4Adaptability or versatility
If separate sensing transformer is used for current and voltage sensing, then sensing function is achieved, but number of parts and connections increases
Solution Approach 1:
The patent integrates multiple functions into a single transformer device. The primary and secondary windings serve dual purposes: power transformation and current sensing. The magnetic core structure enables both power transfer and sensing functions to be achieved with the same components, eliminating the need for separate sensing transformers and reducing the overall number of parts and connections
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 transformer with lower profile, reduced magnetic and copper losses, and improved efficiency, capable of processing 225 watts at 99% efficiency with a profile less than 15 mm, effectively addressing the inefficiencies and space constraints of traditional transformers.
Implementation Method 1
a primary winding wound around the magnetic core, wherein the primary winding comprises one or two turns of a first conductive material; and a secondary winding wound around the magnetic core, wherein the secondary winding comprises a plurality of turns of a second conductive material
Data Source
AI summary
A transformer assembly. In some embodiments, the transformer assembly comprises a transformer, comprising a magnetic core; a primary winding wound around the magnetic core, wherein the primary winding comprises one or two turns of a first conductive material; and a secondary winding wound around the magnetic core, wherein the secondary winding comprises a plurality of turns of a second conductive material, and wherein a diameter of the magnetic core is sized such that the transformer achieves a first inductance with a core loss comparable to a winding loss.