Patent ID: 8869381

Claim:
A method for providing a low profile transformer of predetermined operational and material specifications adaptable into a receiving housing, wherein the transformer comprises a core unit having a pair of core members, each core member having a base portion, an inserting portion, and a pair of lateral portions, the method comprising: providing the receiving housing having a first cross section, defining a first available area in the first cross section for receiving the transformer; determining an actual effective cross-sectional area (A e — act ) of the inserting portion, wherein (A e — act ) is less than the first available area; selecting an available coil winding width (W) of the transformer not greater than the distance between the inserting portion and either one of the lateral portions; applying the predetermined operational and material specifications to a characteristic equation to selectively provide a characteristic effective area function A e (N p , N) and a characteristic magnetic flux variation function ΔB(N p , N), the characteristic equation being defined as A e = V in_min ⁢ D ⁡ ( V in_min , N , V o ) N p ⁢ Δ ⁢ ⁢ B · fre wherein A e denotes an effective cross-sectional area of an inserting portion, V in — min denotes minimum AC (alternating current) input voltage in [V], N denotes winding ratio between primary and secondary windings, V o denotes DC output voltage in [V], D(V in — min , N, V o ) denotes duty cycle, wherein D 1 - D = N ⁢ V 0 V in_min , Np denotes primary winding number, ΔB denotes change in magnetic flux density in [Tesla], fre denotes operating frequency in [KHz]; selecting a suitable solution pair (Np, N) from the solution space of the characteristic effective area function A e (N p , N) or the characteristic magnetic flux variation function ΔB(N p , N); obtaining a secondary coil winding number (Ns) from the solution pair (Np, N) for determining a total required coil winding area (A total ) through the selected Np and the corresponding Ns; and obtaining an available coil winding length (L) of the transformer by dividing the total required coil winding area (A total ) by the available coil winding width (W).