Solving a High-Current Transformer Design Challenge

Background

Our customer, a military and defense contractor, wanted to use flexible circuit technology to build a planar transformer comprised of primary and secondary windings, with very high current carrying capability.

Services & Solutions

Our challenge was to build a circuit with 50 μm line and space and 27 μm traces. We also needed to solve four persistent problems associated with the design requirements:

  1. Very thick copper traces on the surface of thin polymers
  2. Thick bonding layers required to conform to traces and provide insulation between layers
  3. High layer count—ultimately 54 layers
  4. Through-hole issues resulting from thick dielectric and conductor layers

Results

Using systematic process rigor, our engineers were able overcome all four design obstacles and quickly delivered a reliable circuit to our customer.