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EP1536436B1 - Verfahren zur herstellung von planartransformatoren und so hergestellter planartransformator - Google Patents

Verfahren zur herstellung von planartransformatoren und so hergestellter planartransformator Download PDF

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Publication number
EP1536436B1
EP1536436B1 EP03761602.6A EP03761602A EP1536436B1 EP 1536436 B1 EP1536436 B1 EP 1536436B1 EP 03761602 A EP03761602 A EP 03761602A EP 1536436 B1 EP1536436 B1 EP 1536436B1
Authority
EP
European Patent Office
Prior art keywords
windings
printed circuit
resin
insulating
transformer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP03761602.6A
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English (en)
French (fr)
Other versions
EP1536436A1 (de
Inventor
Javier Gazo Pastor
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Premo SA
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Premo SA
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Publication date
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Publication of EP1536436B1 publication Critical patent/EP1536436B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/005—Impregnating or encapsulating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/02—Casings
    • H01F27/022—Encapsulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2804—Printed windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H01F27/325—Coil bobbins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/327—Encapsulating or impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/04—Arrangements of electric connections to coils, e.g. leads
    • H01F2005/043—Arrangements of electric connections to coils, e.g. leads having multiple pin terminals, e.g. arranged in two parallel lines at both sides of the coil
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F2027/297—Terminals; Tapping arrangements for signal inductances with pin-like terminal to be inserted in hole of printed path

Definitions

  • This invention relates to a process for the manufacture of planar transformers and a planar transformer manufactured by means of said process.
  • the object of this invention is to provide planar transformers of very small size and with a large capacity for insulation between layers, in particular between windings, offering the further possibility that they may be manufactured economically.
  • this invention discloses the manufacture of planar transformers comprising solely of windings and insulating layers of variable thickness according to the insulation between integrated circuits and/or windings manufactured by the punching of copper sheets or wound copper, ensuring that there is dielectric strength in the vertical direction.
  • Document US 5,317,300 describes a wholly conventional non-planar transformer with a coil, windings and terminals and a core formed by retention plates. Therefore it relates in fact to a transformer which belongs to a wholly separate stage in the development of transformers. It is cited because unlike the documents mentioned above it describes the total or partial encapsulation of the transformer with a thermoplastic material by injection.
  • US 6 211 767 discloses an example of planar transferences according to the precharacterising portion of claim 1.
  • EP 0 267 822 discloses a flat transformer with a resin encapsulation. However, the transformer being of a different structure, therefore applicable in other fields.
  • Document XP010265713 ISBN: 978-0-7803-3959-0 discloses a method for increasing the insulation in planar magnetics such as void-free encapsulation using an insulating resin.
  • the interleaved insulating layers In order to achieve good penetration by the resin between the windings, it is necessary for the interleaved insulating layers to be of sufficient size to permit such penetration, in order to leave a larger region for penetration by the insulating resin.
  • the box for moulding the assembly of windings, interleaved insulating layers and printed circuits may be incorporated in the transformer for the purpose of acting as an envelope for the assembly, although the transformer may be manufactured in the manner indicated within a metal or shell mould, in which case there is no outer box moulding the polyurethane resin.
  • a planar transformer according to this invention comprises a set of windings and interleaved insulating layers stacked into an assembly joined together by a set of connecting pins as seen in Figure 1 , in which may be seen the printed circuit boards -1- and -2- and intermediate windings -3- and -4-, punched from copper sheet or wound from the same material, the interleaved insulating layers -5-, -6-, -7-, -8- and -9- being located on each side of the said members and having surface dimensions which are smaller than those of printed circuit windings -1- and -2-.
  • the arrangement is that which may be seen in Figures 2 and 3 , in which the arrangement of the windings, printed circuit boards and interleaved insulating layers can be seen, fixed in position through a variable number of through pins, with the pins represented by the numbers -10-, -10'-, -10"- ..., as may be seen in Figure 1 , it being understood that their number and arrangement will depend on the circuits enclosed.
  • These pins are inserted in the corresponding orifices in the printed circuit boards and winding boards as indicated for example by numbers -11-, -11'-, -11"- ... in printed circuit board -1- and numbers -12- and -12'- in winding -3-.
  • pins are attached to the said panels and windings in ways which are known in the art, for example by cold welding, cementing masses or other means.
  • the assembly is embedded in a mass of insulating polyurethane resin which can be achieved by casting in an external or "shell” mould or using a box of appropriate structure -13-, which has an external shape matching that of the printed circuit boards, with lateral steps such as -14- and -15- to match lateral notches -16- and -17- of the said printed circuit boards and an extended central core -18- designed to coincide with the central openings of the said stacked members, that is, printed circuit boards, windings and interleaved insulating layers.
  • ferrite cores -19- and -20- are attached, being joined by laminar insulating members fitted externally thereto or by any other means known in the art.
  • Figure 4 illustrates a plan view of an embodiment of a planar transformer manufactured in accordance with this invention, in which will be seen enclosing box -13-incorporated in the mass of polyurethane resin, forming end blocks -21- and -34- which are interconnected by portions -22- and -23- of which only the beginning can be seen in Figure 4 , edging the central opening -25-.
  • the ends of the connecting pins extend beyond the block of polyurethane resin, being represented by the numbers -26-, -27-, -28- and -29- in the case of block -34- and pins -30-, -31-, -32-and -33- in the case of block -21-, although it should be understood that the number and arrangement of the said pins may vary with the specific design of the planar transformer.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Insulating Of Coils (AREA)

Claims (4)

  1. Planartransformator, der Art umfassend einen Ferritkern (19, 20) und eine Reihenfolge von Wicklungen in einem Stapel, umfassend eine variable Anzahl von gedruckten Leiterplatten (1, 2) und Kupferwicklungen (3, 4), gestanzt aus einer Folie oder gewickelt, mit verschachtelten isolierenden flächigen Elementen (5, 6, 7, 8, 9) in Kontakt mit allen Oberflächen der Wicklungen und mit einer variablen Dicke, um die Lücken zwischen den Wicklungen einzustellen, wobei die genannten Wicklungen mittels Verbindungsstiften (10, 10', 10", 26-33) miteinander verbunden sind, welche durch diese eingesteckt werden, dadurch gekennzeichnet, dass die Verbindungsstifte in ausgerichteten Löcher (11, 11', 11", 12) der gedruckten Leiterplatten (1, 2) und der Kupferwicklungen (3, 4) eingesteckt werden, und der Transformator einen einzigen vormontierten Block (21, 22, 23, 34) umfasst, infolge der Stapelung der gedruckten Leiterplatten und der Kupferwicklungen mit eingesteckten Verbindungsstiften und den verschachtelten isolierenden flächigen Elementen, welche in einer einzigen Masse aus isolierendem Polyurethanharz eingebettet sind, welche die Baugruppe aus gestapelten Elementen äußerlich deckt und welche in die Lücken zwischen den Wicklungen eindringt, wobei der äußerliche Ferritkern außen und an dem vormontierten Block befestigt bleibt.
  2. Planartransformator nach Anspruch 1, dadurch gekennzeichnet, dass der Harzblock, welcher die Wicklungen, die verschachtelten isolierenden flächigen Elemente und die eingesteckten Verbindungsstifte (10, 10', 10", 26-33) des Transformators enthält, innerhalb eines offenen Isolierkastens (13) eingegliedert wird, welcher in die Basis, das seitliche Profil des genannten Blocks und dessen zentrale Öffnung einpasst.
  3. Verfahren zur Herstellung von Planartransformatoren nach den Ansprüchen 1 und 2, ausgeführt durch einen ersten Schritt des vertikalen Stapelns der gedruckten Leiterplatten, der Kupferwicklungen und der verschachtelten isolierenden flächigen Elementen sowohl in oberen als auch in unteren Teilen des Stapels, dadurch gekennzeichnet, dass diese mittels des Einsteckens von Verbindungsstiften, welche in ausgerichtete Löcher der Wicklungen einpassen, fixiert werden, wobei die Stifte mit den genannten Wicklungen befestigt werden und schließlich eine Masse aus Polyurethanharz in eine Form eingegossen wird, welche den zuvor montierten Stapel umfassend die Wicklungen, die verschachtelten isolierenden flächigen Elemente und die eingesteckten Verbindungsstifte umgibt, wobei das Harz bei einer geeigneten Geschwindigkeit eingegossen wird, um zu ermöglichen, dass das isolierende Harz in die Lücken zwischen den Wicklungen eindringt.
  4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass die Masse aus Polyurethanharz in einen umgebenden Kasten (13) eingegossen wird, welches einen versiegelten Boden aufweist und im oberen Teil offen ist, welcher äußerlich der Gestalt des vormontierten Stapels der gedruckten Leiterplatten, der Kupferwicklungen und der verschachtelten isolierenden flächigen Elementen entspricht, sodass er mit Harz gefüllt wird, bis es bündig mit der oberen Oberfläche ist, im einen Block zu bilden.
EP03761602.6A 2002-06-26 2003-06-23 Verfahren zur herstellung von planartransformatoren und so hergestellter planartransformator Expired - Lifetime EP1536436B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ES200201465 2002-06-26
ES200201465A ES2197830B1 (es) 2002-06-26 2002-06-26 Procedimiento para la fabricacion de transformadores planares y transformador planar fabricado de acuerdo con el mismo.
PCT/ES2003/000309 WO2004003947A1 (es) 2002-06-26 2003-06-23 Procedimiento para la fabricación de transformadores planares y transformador planar fabricado de acuerdo con el mismo

Publications (2)

Publication Number Publication Date
EP1536436A1 EP1536436A1 (de) 2005-06-01
EP1536436B1 true EP1536436B1 (de) 2017-01-25

Family

ID=29797398

Family Applications (1)

Application Number Title Priority Date Filing Date
EP03761602.6A Expired - Lifetime EP1536436B1 (de) 2002-06-26 2003-06-23 Verfahren zur herstellung von planartransformatoren und so hergestellter planartransformator

Country Status (4)

Country Link
EP (1) EP1536436B1 (de)
AU (1) AU2003242793A1 (de)
ES (1) ES2197830B1 (de)
WO (1) WO2004003947A1 (de)

Families Citing this family (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4821870B2 (ja) 2009-03-19 2011-11-24 Ｔｄｋ株式会社 コイル部品、トランス、スイッチング電源装置、及びコイル部品の製造方法
KR101105572B1 (ko) * 2010-06-21 2012-01-17 엘지이노텍 주식회사 평면 변압기
US8441331B2 (en) 2011-03-16 2013-05-14 Delphi Technologies, Inc. Planar magnetic structure
DE102011075707A1 (de) * 2011-05-12 2012-11-15 SUMIDA Components & Modules GmbH Transformator mit geblechter Wicklung
CN102791076B (zh) * 2012-08-27 2014-09-03 河南兵峰电子科技有限公司 Pcb平面变压器
US9196414B2 (en) 2012-10-17 2015-11-24 Covidien Lp Planar transformers having reduced termination losses
WO2014062357A1 (en) * 2012-10-17 2014-04-24 Covidien Lp Planar transformers having reduced termination losses
ES2393695B1 (es) * 2012-11-12 2013-08-08 Premo, S.L. Transformador con inductor integrado
US9620278B2 (en) 2014-02-19 2017-04-11 General Electric Company System and method for reducing partial discharge in high voltage planar transformers
KR101579427B1 (ko) * 2015-10-28 2015-12-22 주식회사 에이치에스씨 트랜스포머
ES2808995T3 (es) * 2017-11-30 2021-03-02 Premo Sa Unidad anular de potencia magnética
TWI671769B (zh) * 2018-05-02 2019-09-11 聯寶電子股份有限公司 磁感應元件及其製造方法
CN113539638A (zh) * 2021-07-06 2021-10-22 辽宁意思德电气有限公司 一种大容量电感
WO2023232437A1 (fr) * 2022-05-30 2023-12-07 Valeo Eautomotive France Sas Ensemble et transformateur électrique planaire
KR102647780B1 (ko) * 2022-06-13 2024-03-14 케이에이치필룩스 주식회사 변압 장치
US20240186054A1 (en) * 2022-10-25 2024-06-06 Delta Electronics, Inc. Isolated power supply for gate driver
KR102657251B1 (ko) * 2024-03-07 2024-04-15 주식회사 씨트로닉스 평판코일을 구비한 변압기

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US4622627A (en) * 1984-02-16 1986-11-11 Theta-J Corporation Switching electrical power supply utilizing miniature inductors integrally in a PCB
EP0267822A1 (de) * 1986-10-15 1988-05-18 Electronique Serge Dassault Hochfrequenztransformator mit gedruckter Schaltungswicklung, insbesondere für sehr hohe Spannungsquelle
US5317300A (en) * 1990-03-13 1994-05-31 Boesel Robert P Encapsulated high efficiency transformer and power supply
US6211767B1 (en) * 1999-05-21 2001-04-03 Rompower Inc. High power planar transformer
US6380834B1 (en) * 2000-03-01 2002-04-30 Space Systems/Loral, Inc. Planar magnetic assembly

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US5010314A (en) * 1990-03-30 1991-04-23 Multisource Technology Corp. Low-profile planar transformer for use in off-line switching power supplies
US6000128A (en) * 1994-06-21 1999-12-14 Sumitomo Special Metals Co., Ltd. Process of producing a multi-layered printed-coil substrate
AT1045U1 (de) * 1995-10-03 1996-09-25 Fronius Schweissmasch Spulenkörper und verfahren zu dessen herstellung für einen transformator
DE19629067A1 (de) * 1996-07-18 1998-01-22 Rene Weiner Spulenkörper für eine Flachspule

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4622627A (en) * 1984-02-16 1986-11-11 Theta-J Corporation Switching electrical power supply utilizing miniature inductors integrally in a PCB
EP0267822A1 (de) * 1986-10-15 1988-05-18 Electronique Serge Dassault Hochfrequenztransformator mit gedruckter Schaltungswicklung, insbesondere für sehr hohe Spannungsquelle
US5317300A (en) * 1990-03-13 1994-05-31 Boesel Robert P Encapsulated high efficiency transformer and power supply
US6211767B1 (en) * 1999-05-21 2001-04-03 Rompower Inc. High power planar transformer
US6380834B1 (en) * 2000-03-01 2002-04-30 Space Systems/Loral, Inc. Planar magnetic assembly

Non-Patent Citations (1)

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Title
GUNEWARDENA T.R.: "Manufacturing design considerations for planar magnetics", ELECTRICAL INSULATION CONFERENCE, 1997, AND ELECTRICAL MANUFACTURING & COIL WINDING CONFERENCE. PROCEEDINGS ROSEMONT, IL, USA 22-25 SEPT. 1997, NEW YORK, NY, USA,IEEE, US, 22 September 1997 (1997-09-22), pages 309 - 311, XP010265713, ISBN: 978-0-7803-3959-0 *

Also Published As

Publication number Publication date
ES2197830A1 (es) 2004-01-01
ES2197830B1 (es) 2005-01-01
WO2004003947A1 (es) 2004-01-08
AU2003242793A1 (en) 2004-01-19
EP1536436A1 (de) 2005-06-01

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