Transformer With Interlayer Connection Member For Compact Design

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Solution Overview

Problem

Traditional transformers with patterned conductors on sheet substrates face challenges in maintaining electrical insulation distance, leading to increased resistance and leakage inductance, especially under high voltage conditions, which enlarges the substrate size and affects coupling with the core.

Innovation Solution

The transformer design incorporates a winding member with a core made of magnetic material, where the winding member comprises stacked substrates with patterned conductors that share the electrical insulation space, allowing for a compact size and improved coupling with the core, eliminating the need for curvature in the secondary winding and reducing substrate size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrical insulation distance is increased to maintain insulation under high voltage, then the reliability is improved, but the substrate size is enlarged and the coupling with the core is reduced

Engineering Contradiction:

Improveelectrical insulation distanceVSAvoidsubstrate size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent positions the interlayer connection member in the vertical dimension (stacking direction) between the first and second windings, rather than extending the insulation distance horizontally. This allows the windings to be placed closer together in the planar direction while maintaining adequate insulation through the layered structure, thus reducing substrate size while preserving electrical insulation reliability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The interlayer connection member acts as an intermediary element that provides the necessary electrical insulation between the first and second windings. By introducing this intermediate component in the stacking direction, the patent achieves reliable electrical insulation without requiring increased horizontal spacing, thereby maintaining compact substrate dimensions and good coupling with the core.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the interlayer connection member is positioned far from the core to maintain insulation distance, then the reliability is improved, but the leakage inductance is increased

Engineering Contradiction:

Improveelectrical insulation distanceVSAvoidleakage inductance

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent resolves this contradiction by moving the insulation function to the vertical dimension through the interlayer connection member. This allows the connection member to be positioned close to the core in the horizontal plane (reducing leakage inductance) while maintaining adequate insulation distance in the vertical stacking direction (improving reliability).

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If the patterned conductor is made to curve to maintain insulation distance, then the reliability is improved, but the resistance is increased and the substrate size is enlarged

Engineering Contradiction:

Improveelectrical insulation distanceVSAvoidresistance

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

Instead of curving the patterned conductor in the horizontal plane to create insulation distance, the patent utilizes the vertical stacking dimension. The interlayer connection member provides insulation in the vertical direction, allowing the patterned conductor to remain straight and short in the horizontal plane, thus minimizing resistance while maintaining reliability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 enhances electrical insulation distance management, decreases leakage inductance, and maintains high coupling between windings and the core, preventing resistance increases and allowing for smaller transformer dimensions.

Implementation Method 1

the core member is made of magnetic material, the core member is disposed around the winding member such that the core member forms a magnetic path

Methodology Applied

Scientific EffectMagnetic path formation: Magnetism

Implementation Method 2

The patterned conductor of the first substrate is defined by a one-turn patterned conductor which has one turn, whereby the patterned conductor of the first substrate defines a first winding. The patterned conductor of each the second substrate defines a second winding.

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP2284847B1Transformer, power converter using the transformer, lighting device, lamp for vehicle, and vehicle

Publication Date: 2019.06.05 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

Figure 1A
Figure 1B
Figure 2

AI summary

A transformer in this invention comprises substrates constructing a primary winding, substrates constructing the secondary winding, and a core member disposed around the substrates. The substrates defining the primary winding are provided with insertion holes for passing a middle leg portion of the core member, and patterned conductors having one turn. The transformer further comprises an interlayer connection member. The interlayer connection member is located inwardly of the patterned conductors of the substrates defining the primary winding. The interlayer connection member is located on the same side of the patterned conductors defining the primary winding. The interlayer connection member is configured to establish the electrical connection of the patterned conductors defining the primary winding.