CN101651008A - 电感元件 - Google Patents
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Abstract
一种电感元件,包括磁芯,该磁芯具有容纳在多层电路板的每层中所限定的中心开口中的部分。由位于电路板的多层上的金属线圈形成初级绕组、辅助绕组和次级绕组中的每一个。通过相对厚的电介质层将次级绕组与其他绕组分开。其他电介质层将具有线圈的各层分开。在其他层上设置EMI屏蔽。线圈位于每层的中心区域,从而提供与电感元件侧边的足够的安全裕度。
Description
技术领域
本发明涉及一种变压器,具体地,涉及一种电感元件。
背景技术
这里提到的是在能量转换装置中使用的技术。通常,能量转换器是一种将能量传输到电子装置的电源单元,并且还可以调节电流以符合装置的特殊要求。一般将能量转换器用于消费型电子装置中,例如计算机、膝上型电脑、音响装置、蜂窝式便携无线电话等。
一种类型的能量转换器是开关式电源(SMPS,Switched Mode PowerSupplies)。SMPS可以包括电源单元以及在单元内以调节电流的电路。电路运行非常快,调节电流从而可以使其稳定到设定的电压,该电压直接发送到装置。由于重量、经济和便利因素,SMPS是向需要稳定的电流和电压的大部分消费者电子装置提供动力的备选装置。但是,必须仔细设计它们以提供具有可接受的效率和最小噪音的动力。
为了符合这些要求,能量转换器可以包括一级或多级,该级包括一个或多个磁部件,该磁部件包括滤波器、变压器、电感器等。通常,这里所描述的技术指向能量转换器所利用的各种磁部件的改进。
发明内容
结合系统、工具和方法来描述并示出随后的实施例及其特点,它们是代表性的和示例性的,并没有限制范围。在各种实施例中,减小或消除了上述的一个或多个问题,同时其他实施例教导其他的改进。
所公开的内容是一种电感元件,其包括多层电路板,其中每层电路板都包括在其内限定的中心开口。电路板中的多个层包括在层上由导电材料形成的线圈,电流能从线圈中流过,并且这些线圈中的一个或多个组成初级绕组以及这些线圈中的一个或多个组成次级绕组。电路板中的其他多个层作为电介质层以使线圈彼此分开,并且通过足够的安全裕度使初级绕组和次级绕组分开。在电路板中穿过的导线使选中的线圈互连以形成初级和次级绕组。还包括磁芯,磁芯的一部分容纳在电路板的中心开口内。
可以在电路板的层上的中心区域内设置线圈以沿着电路板的侧边提供足够的安全裕度。其他多个层可以组成EMI屏蔽。可以将初级绕组和次级绕组分开至少约10密耳(mils)。可以将初级绕组和次级绕组分开至少约14密耳。可以通过具有约小于5密耳的厚度的电介质层将初级绕组的多个线圈彼此分开。可以通过具有约3密耳或更小的厚度的电介质层将初级绕组的多个线圈彼此分开。多层电路板可以是矩形的,该矩形的长度充分地大于矩形的宽度。中心开口可以是椭圆形的。一个或多个线圈可以组成辅助绕组。
这里所公开的内容是一种具有多层电路板的电感元件,其中电路板的每一层都包括在其内限定的中心开口。至少按以下顺序包括以下的层:第一EMI屏蔽层;第一电介质层;初级绕组的第一线圈层;第二电介质层;初级绕组的第二线圈层;第三电介质层;初级绕组的第三线圈层;第四电介质层;初级线圈的第四线圈层;第五电介质层;初级线圈的第五线圈层;第六电介质层;初级绕组的第六线圈层;第七电介质层;初级绕组的第七线圈层;第八电介质层;初级绕组的第八线圈层;第九电介质层;辅助绕组的第一线圈层;第十电介质层;辅助绕组的第二线圈层;第二EMI屏蔽层;实质上比其他电介质层的大多数厚的第十一电介质层;次级绕组的第一线圈层;第十二电介质层;次级绕组的第二线圈层;第十三电介质层;以及第三EMI屏蔽层。还包括磁芯,将其一部分容纳在电路板的中心开口中。
除了上述示例性的特点和实施例,通过参照附图并研究随后的说明,更多的特点和实施例将变得显而易见。
附图说明
图1是在隔离层所分开的各层上具有一对绕组的多层电路板的分解图示。
图2示出了具有横穿几层分布的三个绕组为一组的多层电路板的分解图,其中通过隔离板将次级绕组与其他绕组分开。
图3示出了图2的组装的多层电路板。
图4示出了图2的组装的多层电路板的横截面图。
具体实施方式
本发明易于进行各种修改和可替换的形式,所以通过在附图中示例的方式示出了其具体实施例并且在这里进行详细说明。但是,应该理解的是,其并不意味着将本发明限制到所公开的特殊形式,而是本发明覆盖落在由权利要求所限定的本发明的范围和精神内的全部修改、等价形式和替换方案。
通常,AC到DC转换器在初级和次级绕组之间需要高压隔板以符合新产品承诺实验室(UL,Underwriters Laboratories)和国际安全标准。对于标准的绕组式变压器,典型地用缠绕在初级和次级绕组之间的挡墙胶带(margin tape)来作为隔板,或者通过使用用于初级绕组或次级绕组的三层绝缘线来作为隔板。
另一方面,通常,通过安置绕组作为多层PC板上的迹线,然后将变压器磁芯增加到PC板来得到平面型磁性变压器。在平面型变压器中,这比较难形成安全隔板。
在电流型平板变压器中,可以在单独的PC板上形成初级和次级绕组。然后将PC板放置在高绝缘的塑料护罩内,或者在将PC板放置在一起并增加变压器磁芯之前,将挡墙胶带放置在一个或两个板周围。但是,该方法成本高并且需要大量劳力。分别形成两个PC板并将它们连接在一起,取消了平板型磁性元件的一个驱动因素,这与通过制造方法制成的用于变压器的变压器参数的可重复性相关。
图1示出了电感元件(或变压器)10的部分,包括电路板的至少三个不同的层12、14和16。层12包括由导电材料形成的线圈18,它可以组成初级绕组。层16包括由导电材料形成的线圈20,它可以组成次级绕组。层14是分别在层12和16上的线圈18和20之间的绝缘或隔离层。层14上的虚线22示出了在其上和其下的包含线圈18和20的层的区域。这示出了在线圈18和20(尤其是次级绕组的线圈20)之间以及电感元件10的侧边形成的裕度(margin)。当然,可以设置磁芯(未示出)并且其可以延伸穿过在层12、14和16中限定的开口(未示出),从而磁芯穿过线圈18和20的中心。
如所示,这里教导的变压器10中的PC板层12、14和16以这样的方式布置以确保在初级和次级层之间具有足够的间隔,并且从电路板边缘充分插入至少在次级层中的绕组以提供充足的安全间隔。最终,单个电路板能够支撑初级和次级绕组。
作为足够的安全裕度(safety margin)的一个例子,ULTM标准6950规定了在变压器内部次级绕组应该与其他绕组分开至少0.4mm的距离,并且在变压器外部至少分开5mm的距离。
进一步的细节由图2示出,图2示出了由多层电路板制成的电感元件30。如所示,电感元件30包括由上部和下部组成的磁芯32,上部包括顶壁34、中心腿36以及一对侧壁38和40,下部由底壁42组成。当组装电感元件时,中心腿36以及侧腿38和40接触底壁42并且允许磁通线流过磁路。磁芯32的材料可以是ACMETMP46。
夹置在磁芯32的上部和下部之间的是多层电路板的多个层。如图2所示,这些层包括第一EMI屏蔽44、第二EMI屏蔽46(虽然由于制造该板的方式导致该图示出两个分开的层,但是可以将这些屏蔽称为单个的、上部EMI屏蔽44/46)、第一电介质层48(由于结构上的原因其可以比其他层相对厚)、作为另一个EMI屏蔽的铜层50(注意,每个EMI屏蔽具有从开口到外部边缘形成的狭缝从而不会作为一匝线圈)、第二电介质层52、第一线圈层54、第三电介质层56、第二线圈层58(注意,第一和第二线圈层包括以彼此相反的方向缠绕的线圈,使得当在层之间把邻近的线圈层电连接在一起时,可以通过线圈内部的隐蔽埋入孔形成连接,或者以可替换的方式,通过沿着层的外部边缘的边缘连接(edge connection)来形成该连接)、第四电介质层60、第三线圈层62、第五电介质层64、第四线圈层66、第六电介质层68、第五线圈层70、第七电介质层72、第六线圈层74、第八电介质层76、第七线圈层78、第九电介质层80、第八线圈层82(将这前八个线圈层连接在一起以形成初级绕组)、第十电介质层84、第九线圈层86、第十一电介质层88、第十线圈层90(将这后两个线圈层86和90连接在一起以形成辅助绕组)、第十二电介质层92、第三EMI屏蔽94、比第二至第十二电介质层52、56、60、64、68、72、76、80、84、88和92厚得多以作为安全间隔体的第十三电介质层96、在第十一线圈层100的顶部上电镀的电镀层98(将这两个层一起称为线圈层98/100)、第十四电介质层102、其上设置了电镀层106的第十二线圈层104(将这两个层一起称为线圈层104/106)、第十五电介质层108、第四EMI屏蔽110以及第五EMI屏蔽112(将这些屏蔽称为单个的、下部EMI屏蔽110/112)。注意,第一、第十三和第十五电介质层48、96和108可以具有在15密耳范围内的厚度,而其余电介质层52、56、60、64、68、72、76、80、84、88、92和102可以具有在3密耳范围内的厚度。铜层50和90可以具有大约1.2密耳的厚度。电镀层98和106可以具有大约1.0密耳的厚度。
每个层44-112可以具有在其中限定的中心开口以容纳磁芯的中心腿36。第一到第九线圈层54、58、62、66、70、74、78、82和86可以由铜形成并且可以具有大约1.2密耳的厚度,而第十一和第十二线圈层100和104也可以由铜形成,但是它们可以具有大约0.6密耳的厚度。可以电镀形成第一和第五EMI屏蔽44和112并且它们可以具有大约1.2密耳的厚度,而第二、第三和第四EMI屏蔽46、94和110可以由铜形成并且第二和第四屏蔽46和110可以具有大约0.6密耳的厚度,而第三屏蔽94可以具有大约1.2密耳的厚度。
如上所述,可以将第一至第八线圈层54、58、62、66、70、74、78和82连接在一起以形成初级绕组,而将线圈层86和90连接在一起以形成辅助线圈,并且将线圈层98/100和102/104连接在一起以形成次级绕组。
如所示,增加了空层96以在初级和次级绕组之间产生足够的间隔。而且,从PC板的边缘插入绕组以提供足够的电介质来满足安全要求。在图中增加线120以示出电路板的外边缘。可以看出,虽然电介质层延伸到线120,但是形成次级绕组的层98、100、104和106没有延伸到线120。该间隔在次级绕组的侧面提供了足够的安全裕度。应该理解的是,“空层”可以包括迹线,只要符合间隔要求。在至少一个实施例中,在所有方向上绕组和电路板的边缘之间都具有相等的间隔。
图3示出了电感元件10的组装后的层,磁芯32没有在其本来的位置。图4示出了组装后的层的剖面图。如所示,清楚地看到了EMI屏蔽44/46、50、94和110/112。在EMI屏蔽44/46和94之间,可以看到初级和辅助绕组的各个线圈层。在EMI屏蔽94和110/112之间,可以看到次级绕组的线圈层98/100和102/104。夹置在这些层之间的是各个电介质层。注意,次级绕组的线圈层98/100和102/104比其他绕组的线圈层厚些。而且,如图2所示,层98/100和102/104的导电区域非常宽,并且具有将它们分开的狭缝。这与用于初级和辅助绕组的线圈层的相对狭窄的迹线形成对比。由于与在初级绕组中达到约0.4安培的电流相比,可以穿过次级绕组的电流,可以达到2.5安培(amps),所以设置了在次级绕组中电流能流过的该较大容积(volume)。
还可以理解的是,初级绕组(当把全部线圈层连接在一起时)可以具有大约40-42匝,而辅助绕组可以具有6-8匝,并且次级绕组可以只具有大约3匝。
正如可以理解的,这里教导的技术提供了在单个的多层电路板中用于电感元件的容易地并且可重复地制造的设计。而且,该设计在初级和次级绕组之间提供了足够的安全层。最后,该设计在每层的外围提供了足够的安全层。
虽然在附图和前述说明中示出并详细描述了本发明,但是,应把这样的示例和说明看作示例性的并且没有相应的限制。例如,上述的有些实施例可以与其他描述的实施例结合和/或以其他方式设置(例如,可以以其他的顺序执行方法步骤)。因此,应该理解的是,只是示出并描述了优选实施例及其变化,并且希望保护在本发明精神的范围内的全部改变和修改。
本申请要求2008年5月28日提交的题目为“用于能量转换的技术”的美国临时申请No.61/056,706的优先权,其全部内容在此引作参考。
Claims (12)
1、一种电感元件,包括:
多层电路板,其中所述电路板的每层都包括在所述每层中限定的中心开口,其中:
所述电路板中的多个层包括在层上由导电材料形成的线圈,电流能流过该线圈,此外,所述线圈中的一个或多个组成初级绕组,所述线圈中的一个或多个组成次级绕组;
所述电路板中的多个其他层作为电介质层以使所述线圈彼此分开,并且通过足够的安全裕度将所述初级绕组和所述次级绕组分开;以及
所述电路板中的穿通导线,使选中的所述线圈互连以形成所述初级绕组和所述次级绕组;以及
磁芯,所述磁芯的一部分容纳在所述电路板的中心开口内。
2、如权利要求1限定的电感元件,其中所述线圈设置在所述电路板的层上的中心区域内以沿着所述电路板的侧边提供充足的安全裕度。
3、如权利要求1限定的电感元件,其中多个其他层组成EMI屏蔽。
4、如权利要求1限定的电感元件,其中将所述初级绕组和所述次级绕组分开至少大约10密耳。
5、如权利要求4限定的电感元件,其中将所述初级绕组和所述次级绕组分开至少大约14密耳。
6、如权利要求5限定的电感元件,其中通过具有小于约5密耳的厚度的电介质层将所述初级绕组的多个线圈彼此分开。
7、如权利要求6限定的电感元件,其中通过具有约3密耳或更小的厚度的电介质层将所述初级绕组的多个线圈彼此分开。
8、如权利要求1限定的电感元件,其中所述多层电路板是矩形的,所述矩形的长度实质上大于所述矩形的宽度。
9、如权利要求8限定的电感元件,其中所述中心开口是椭圆形的。
10、如权利要求1限定的电感元件,其中所述中心开口是椭圆形的。
11、如权利要求1限定的电感元件,其中一个或多个所述线圈组成辅助绕组。
12、一种电感元件,包括:
多层电路板,其中所述电路板的每层都包括在所述层中限定的中心开口,且至少按以下顺序包括以下的层:
第一EMI屏蔽层;
第一电介质层;
初级绕组的第一线圈层;
第二电介质层;
所述初级绕组的第二线圈层;
第三电介质层;
所述初级绕组的第三线圈层;
第四电介质层;
所述初级线圈的第四线圈层;
第五电介质层;
所述初级线圈的第五线圈层;
第六电介质层;
所述初级绕组的第六线圈层;
第七电介质层;
所述初级绕组的第七线圈层;
第八电介质层;
所述初级绕组的第八线圈层;
第九电介质层;
辅助绕组的第一线圈层;
第十电介质层;
所述辅助绕组的第二线圈层;
第二EMI屏蔽层;
实质上比大多数其他电介质层厚的第十一电介质层;
次级绕组的第一线圈层;
第十二电介质层;
所述次级绕组的第二线圈层;
第十三电介质层;以及
第三EMI屏蔽层;以及
磁芯,所述磁芯的一部分容纳在所述电路板的所述中心开口内。
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- 2009-05-28 US US12/474,016 patent/US8031042B2/en active Active
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Also Published As
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US20090295531A1 (en) | 2009-12-03 |
US20090295524A1 (en) | 2009-12-03 |
US20090295527A1 (en) | 2009-12-03 |
US20090295528A1 (en) | 2009-12-03 |
CN101651015A (zh) | 2010-02-17 |
CN101661825A (zh) | 2010-03-03 |
CN101661825B (zh) | 2013-10-30 |
CN101651008B (zh) | 2013-02-20 |
US8031042B2 (en) | 2011-10-04 |
CN103559977A (zh) | 2014-02-05 |
CN101651024A (zh) | 2010-02-17 |
CN103559978A (zh) | 2014-02-05 |
US8975523B2 (en) | 2015-03-10 |
CN103489564A (zh) | 2014-01-01 |
US7948348B2 (en) | 2011-05-24 |
CN103489564B (zh) | 2017-04-12 |
CN103559977B (zh) | 2016-08-17 |
US7987581B2 (en) | 2011-08-02 |
US8928449B2 (en) | 2015-01-06 |
US20090295529A1 (en) | 2009-12-03 |
CN101651024B (zh) | 2012-10-31 |
CN101651015B (zh) | 2013-02-20 |
CN103559978B (zh) | 2016-08-17 |
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