CN110233028A - 一种平面变压器的pcb板及其制作方法 - Google Patents

一种平面变压器的pcb板及其制作方法 Download PDF

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CN110233028A
CN110233028A CN201910477789.2A CN201910477789A CN110233028A CN 110233028 A CN110233028 A CN 110233028A CN 201910477789 A CN201910477789 A CN 201910477789A CN 110233028 A CN110233028 A CN 110233028A
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hole
sided
pcb substrate
winding section
magnetic core
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查小月
欧阳过
任菁菁
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Apple Inc
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Shenzhen Sunlord Electronics Co Ltd
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Priority to CN201910477789.2A priority Critical patent/CN110233028A/zh
Publication of CN110233028A publication Critical patent/CN110233028A/zh
Priority to PCT/CN2019/115912 priority patent/WO2020244141A1/zh
Priority to KR1020207000492A priority patent/KR102304788B1/ko
Priority to US17/540,256 priority patent/US20220093320A1/en
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Abstract

本发明公开了一种平面变压器的PCB板及其制作方法，包括：在具有一通孔的PCB基板的双面进行胶体注塑，形成一与所述PCB基板一体的双面绕线部；所述双面绕线部在所述PCB基板的双面为对称结构，其中心为与所述通孔一致的过孔，且所述过孔与所述通孔对齐，形成供磁芯穿过的磁芯孔；所述过孔的周边凸起形成挡线部；所述磁芯孔的孔壁上具有过线槽，用于供一条金属导线穿过以在所述双面绕线部两面同时进行由内而外的平面绕线，从而形成位于所述PCB基板双面的两个串联线圈。本发明无需在PCB基板两面涂覆自粘层，减小了涂覆自粘层的时间，并解决了由于自粘层在烘烤过程中会发生流动现象，黏贴的自粘层会在绕线过程中出现积聚现象等一系列问题。

Description

一种平面变压器的PCB板及其制作方法
技术领域
本发明涉及一种平面变压器的PCB板及其制作方法。
背景技术
一般传统变压器为绕线型变压器，是将线圈绕在骨架上并用磁芯组装而成或者直接在磁环上进行绕线。此类产品结构复杂，产品体积较大；降成本能力低；设备成本投入大，换型难度高；产品一致性、稳定性差、潜在失效风险高等；而对于在内部空间小、对节能和散热要求苛刻和在国防、航空、航天等对重量和稳定性要求较高的领域,现如今平面变压器在逐步发挥较大的作用，但平面变压器也有较大缺点，对于多层数叠加绕组，PCB板工艺复杂，成本昂贵。
以上背景技术内容的公开仅用于辅助理解本发明的发明构思及技术方案，其并不必然属于本专利申请的现有技术，在没有明确的证据表明上述内容在本专利申请的申请日前已经公开的情况下，上述背景技术不应当用于评价本申请的新颖性和创造性。
发明内容
本发明的主要目的在于提出一种具有胶体注塑一体成型的双面绕线部并且可通过自动绕线设备自动同时双面绕线的PCB板及其制作方法，以解决平面变压器应用时PCB板工艺复杂以及多层叠加绕组绕线效率低的问题。
本发明为达上述目的提出以下技术方案：
一种平面变压器的PCB板，包括PCB基板，还包括通过胶体注塑形成于所述PCB基板的双面并与所述PCB基板成为一体的双面绕线部；所述PCB基板具有一通孔；所述双面绕线部在所述PCB基板的双面为对称结构，其中心为与所述通孔一致的过孔，且所述过孔与所述通孔对齐，形成供磁芯穿过的磁芯孔；所述过孔的周边凸起形成挡线部；所述磁芯孔的孔壁上具有过线槽，用于供一条金属导线穿过以在所述双面绕线部两面同时进行由内而外的平面绕线，从而形成位于所述PCB基板双面的两个串联线圈。
优选地，所述过线槽包括位于所述通孔孔壁上的一第一凹槽以及位于所述双面绕线部双面的两个挡线部上的两个第二凹槽。
优选地，所述一条金属导线包括单股铜线或者多股铜线。
优选地，所述PCB基板的所述通孔为圆形、椭圆形或矩形。
优选地，所述金属导线包覆有自粘层；当在所述双面绕线部上进行绕制时，通过加热实现边绕制边固定而形成线圈。
优选地，绕制在所述双面绕线部两面的两个线圈，每个线圈仅在最外圈具有一个引线端，所述引线端焊接到所述PCB基板上相应的PIN孔。
本发明上述技术方案，无需在PCB基板两面涂覆聚酰亚胺薄膜或其他能使自粘线粘附在PCB板上的自粘层。这样不仅减小了涂覆自粘层的时间，而且也解决了由于涂覆的自粘层在烘烤过程中会发生流动现象，黏贴的自粘层会在绕线过程中出现积聚现象等一系列问题。所提出的这种平面变压器PCB板，不仅制程缩短，成本减少，也减小了人为因素的影响，产品合格率和产品一致性得到了保证。
为达前述目的，本发明另还提出了一种平面变压器的PCB板的制作方法，包括：提供一具有通孔的PCB基板；在所述PCB基板的两面进行胶体注塑，形成与所述PCB基板一体的双面绕线部；其中，所述双面绕线部在所述PCB基板的双面为对称结构，其中心为与所述通孔一致的过孔，且所述过孔与所述通孔对齐，形成供磁芯穿过的磁芯孔；所述过孔的周边凸起形成挡线部；在所述磁芯孔的孔壁上设置过线槽；所述过线槽用于供一条金属导线穿过以在所述双面绕线部两面同时进行由内而外的平面绕线，从而形成位于所述PCB基板双面的两个串联线圈。
优选地，采用半自动CNC绕线机将一条金属导线穿过所述过线槽，在所述双面绕线部的两面同时进行由内而外的绕制，绕制完成后得到的两个串联线圈，每个线圈仅有一个位于最外圈的引线端。
优选地，所述过线槽包括位于所述通孔孔壁上的一第一凹槽以及位于所述双面绕线部双面的两个挡线部上的两个第二凹槽。
优选地，所述PCB基板的所述通孔为圆形、椭圆形或矩形。
附图说明
图1是本发明平面变压器PCB板的PCB基板立体示意图；
图2是图1所示的PCB基板的俯视图；
图3是本发明具体实施例的一种平面变压器PCB板的俯视图；
图4是图3所示的PCB板的主视图；
图5是图3所示的PCB板上的双面绕线部结构示意图；
图6是图5所示的双面绕线部的俯视图；
图7是在图3所示的PCB板上双面绕线的示意图；
图8和图9是图1所示PCB基板的另外两种变形。
具体实施方式
下面结合附图和具体的实施方式对本发明作进一步说明。
本发明的具体实施方式提出一种平面变压器的PCB板，所述平面变压器主要是应用于手机快充电源适配器上，也可以用在平板电脑、新能源汽车电源适配器上；而本发明提出的所述PCB板，无需再在表面涂覆自粘层，而是通过胶体注塑成型的方式在PCB基板上形成一体的双面绕线部进行双面平面绕线，从而可以免去因涂覆自粘层所带来的人工成本以及避免自粘层二次受热时所带来一系列问题。
参考图1至图7，本发明具体实施例所提出的平面变压器PCB板，包括PCB基板1以及通过胶体注塑形成于该PCB基板的双面并与该PCB基板成为一体的双面绕线部2。如图1和图2所示，该PCB基板1具有一个较大的通孔10，是供变压器的磁芯穿过的，该通孔10的孔壁上具有一第一凹槽101；该PCB基板的周边设有若干PIN孔11。如图3至图6所示，注塑形成的双面绕线部2，在所述PCB基板1的双面为对称结构，其中心为与所述通孔10一致的过孔20，该过孔20与所述通孔10对齐并形成供磁芯穿过的磁芯孔。而过孔20的周边凸起的一圈形成挡线部21，双面的两个挡线部21上与第一凹槽对应的位置处也具有第二凹槽210，第一凹槽101与两个第二凹槽210共同形成过线槽30。如图7所示，采用一条完整的金属导线穿过所述过线槽30，可以在双面绕线部2的两面22同时进行绕线，从内圈往外圈平面绕线，从而在两面各形成一个平面线圈40，并且两个平面线圈是串联的，每个线圈仅在最外圈(绕线结束处)有一个引线端41，所述引线端41即用于焊接到PCB基板上相应的的PIN孔11。
应当理解的是，上面所述的“一条完整的金属导线”可能是一条单股铜线，也可以是两股以上的铜线构成的一条导线，所谓“一条”是强调只有两头的两个线端。在本发明的PCB板上进行绕线时，可以采用半自动的CNC绕线设备进行α绕线，所采用的导线可以是包覆有自粘层的铜线，在自动绕线过程中，绕线设备可以边绕制边加热使导线得以固定。另外，由于有挡线部21的存在，导线从内圈开始往外绕制时，最内圈被挡线部挡住而得以固定线圈的形状。
在如图1至图7所示的实施例中，PCB基板1的通孔是圆形，相应地，注塑的双面绕线部2的过孔也是圆形，适用于圆形的磁芯。但本发明并不对适用的磁芯作出限制，即本发明的PCB基板的通孔还可以是其他形状，比如矩形、椭圆形等，如图8和图9所示。也即，所述磁芯孔可以是矩形、椭圆形等其他的形状。则，相应地，所绕制的线圈为矩形线圈、椭圆线圈。
另外，本发明另一具体实施例还提出了基于前述PCB板的平面变压器的制作方法，包括如下步骤：
提供一具有通孔的PCB基板，比如图1、图8和图9所示的PCB基板；然后，在所述PCB基板的两面进行胶体注塑，形成与所述PCB基板一体的双面绕线部；接着，进行绕线：采用自动绕线设备，将其上已形成有双面绕线部的PCB板夹在绕线机的治具上，用夹头夹住导线从PCB板的磁芯孔穿过并卡入过线槽，此时两面可同时开始绕线，绕完之后将引线端焊接到对应的PIN孔。绕线方式可由单股单层、单股多层、单层多股线或者Liz线并排方式、多股线或者Liz线多层并排方式进行。图7所示例的为单层绕线。最后装上磁芯即可形成平面变压器。
在优选的实施例中，考虑到导线在过线槽处是弯折的，容易出现导线表面的绝缘层破损而与磁芯导通，导致变压器的耐压值达不到要求，本发明在制作该种平面变压器时，在磁芯上、与过线槽相对应的位置处涂覆绝缘漆以避免上述情况发生时导线与磁芯直接导通的问题，从而保证了变压器耐压值能够达到要求。
此类变压器体积小，器件高度较低的优点；并且，在同等功率下，体积通常比传统绕线型变压器至少小1/4以上；还具有结构紧凑、坚固、可靠性高、一致性高；绕组排列整齐，漏感小；EMI辐射干扰低等多个优点。
另一方面，又由于整个过程都是绕线机自动完成的，缩短了制程时间，减小了人为的因素的影响，相应的产品合格率和产品一致性会有更好的保证。
以上内容是结合具体的优选实施方式对本发明所作的进一步详细说明，不能认定本发明的具体实施只局限于这些说明。对于本发明所属技术领域的技术人员来说，在不脱离本发明构思的前提下，还可以做出若干等同替代或明显变型，而且性能或用途相同，都应当视为属于本发明的保护范围。

Claims (10)

1.一种平面变压器的PCB板，包括PCB基板(1)，其特征在于：还包括通过胶体注塑形成于所述PCB基板的双面并与所述PCB基板成为一体的双面绕线部(2)；
所述PCB基板(1)具有一通孔(10)；
所述双面绕线部(2)在所述PCB基板(1)的双面为对称结构，其中心为与所述通孔(10)一致的过孔(20)，且所述过孔(20)与所述通孔(10)对齐，形成供磁芯穿过的磁芯孔；
所述过孔(20)的周边凸起形成挡线部(21)；
所述磁芯孔的孔壁上具有过线槽(30)，用于供一条金属导线穿过以在所述双面绕线部(2)两面同时进行由内而外的平面绕线，从而形成位于所述PCB基板双面的两个串联线圈。
2.如权利要求1所述的PCB板，其特征在于：所述过线槽包括位于所述通孔(10)孔壁上的一第一凹槽(101)以及位于所述双面绕线部(2)双面的两个挡线部(21)上的两个第二凹槽(210)。
3.如权利要求1所述的PCB板，其特征在于：所述一条金属导线包括单股铜线或者多股铜线。
4.如权利要求1所述的PCB板，其特征在于：所述PCB基板的所述通孔为圆形、椭圆形或矩形。
5.如权利要求1所述的PCB板，其特征在于：所述金属导线包覆有自粘层；当在所述双面绕线部上进行绕制时，通过加热实现边绕制边固定而形成线圈。
6.如权利要求1所述的PCB板，其特征在于：绕制在所述双面绕线部两面的两个线圈，每个线圈仅在最外圈具有一个引线端，所述引线端焊接到所述PCB基板上相应的PIN孔。
7.一种平面变压器的PCB板的制作方法，其特征在于，包括：
提供一具有通孔的PCB基板；
在所述PCB基板的两面进行胶体注塑，形成与所述PCB基板一体的双面绕线部；其中，所述双面绕线部在所述PCB基板的双面为对称结构，其中心为与所述通孔一致的过孔，且所述过孔与所述通孔对齐，形成供磁芯穿过的磁芯孔；所述过孔的周边凸起形成挡线部；
在所述磁芯孔的孔壁上设置过线槽；所述过线槽用于供一条金属导线穿过以在所述双面绕线部两面同时进行由内而外的平面绕线，从而形成位于所述PCB基板双面的两个串联线圈。
8.如权利要求7所述的制作方法，其特征在于，采用半自动CNC绕线机将一条金属导线穿过所述过线槽，在所述双面绕线部的两面同时进行由内而外的绕制，绕制完成后得到的两个串联线圈，每个线圈仅有一个位于最外圈的引线端。
9.如权利要求7所述的制作方法，其特征在于，所述过线槽包括位于所述通孔孔壁上的一第一凹槽以及位于所述双面绕线部双面的两个挡线部上的两个第二凹槽。
10.如权利要求7所述的制作方法，其特征在于，所述PCB基板的所述通孔为圆形、椭圆形或矩形。
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