Transformer with Stacked Plates and Insulated Wire
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Solution Overview
Problem
Power supply transformers face challenges in reducing size and leakage inductance while meeting safety insulation requirements, with existing solutions like planar transformers being costly and inefficient due to multiple layers of insulation that block heat transfer and increase cost.
Innovation Solution
A transformer design featuring multiple conductor plates, a plate positioning member, and an insulated wire wound around the member between the plates, which minimizes leakage inductance and maintains safety insulation without excessive reinforcement, allowing for high-frequency operation and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of insulation are added to meet safety requirements, then safety insulation is improved, but device size increases and heat transfer is blocked
Solution Approach 1:
The patent transitions from traditional planar winding to a three-dimensional stacked configuration where primary and secondary windings are arranged in alternating layers around a central axis. This vertical stacking allows insulation to be implemented between discrete layers rather than requiring extensive lateral spacing, thereby maintaining safety insulation while reducing overall transformer volume.
Solution Approach 2:
The patent implements a nested structure where multiple winding layers are concentrically arranged around a central magnetic core. Each winding layer is positioned within the radial space of adjacent layers, creating a compact nested configuration that maximizes space utilization while maintaining required insulation distances between primary and secondary windings.
2Reliability
If conductor spacing is increased to meet safety requirements, then safety insulation is improved, but leakage inductance increases
Solution Approach 1:
The patent arranges windings in a vertical stacked configuration around a central axis, allowing insulation to be provided in the radial direction between layers rather than requiring increased axial or lateral spacing. This dimensional reorganization maintains tight coupling between windings (reducing leakage inductance) while satisfying insulation requirements through inter-layer positioning.
Solution Approach 2:
The patent divides the windings into discrete segmented layers alternating between primary and secondary windings. Each layer is electrically isolated from adjacent layers of opposite polarity by insulation, creating a segmented structure that maintains electrical separation without requiring excessive spacing between conductors, thus limiting leakage inductance.
3Volume of stationary object
If high frequency operation is implemented to reduce transformer size, then device size is reduced, but leakage inductance becomes more problematic
Solution Approach 1:
The stacked radial configuration concentrates windings in the radial dimension around the magnetic core, maximizing magnetic coupling efficiency. This tight radial arrangement minimizes leakage flux paths, making the transformer suitable for high-frequency operation where low leakage inductance is critical, while the compact structure achieves size reduction.
Solution Approach 2:
The alternating primary-secondary layer segmentation creates multiple small coupling zones distributed around the core, each contributing to low leakage inductance. The segmented structure ensures tight magnetic coupling at high frequency while maintaining electrical isolation, enabling high-frequency operation with reduced size.
4Object-generated harmful factors
If interleaved winding structure is used to reduce leakage inductance, then leakage inductance is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent implements interleaving in the radial dimension through alternating layers, which can be manufactured by sequentially winding or stacking pre-formed conductor layers around the magnetic core. This radial interleaving approach is more manufacturable than traditional axial interleaving, as each layer can be independently positioned and insulated, simplifying the manufacturing process while achieving low leakage inductance.
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 design achieves reduced leakage inductance and meets safety insulation standards while minimizing size and cost, enabling efficient power transfer and heat dissipation.
Implementation Method 1
an insulated wire wound around the plate positioning member and between the first and second conductor plates
Implementation Method 2
Power supply transformers provide the isolation barrier between the high AC input voltage and the low DC output voltages
Implementation Method 3
The magnetic core includes a portion surrounded by the plate positioning member, the first conductor plate, the second conductor plate, and the insulated wire
Data Source
AI summary
A transformer. The transformer includes a first conductor plate, a second conductor plate, a plate positioning member, an insulated wire, and a magnetic core. The second conductor plate is spaced apart from and electrically connected to the first conductor plate. The plate positioning member is in contact with and surrounded by the first and second conductor plates. The insulated wire is wound around the plate positioning member and between the first and second conductor plates. The magnetic core includes a portion surrounded by the plate positioning member, the first conductor plate, the second conductor plate, and the insulated wire.