CN113555196A

CN113555196A - Transformer module and power module

Info

Publication number: CN113555196A
Application number: CN202110657236.2A
Authority: CN
Inventors: 蔡超峰; 辛晓妮; 曾剑鸿; 洪守玉; 吴睿; 叶浩屹; 叶益青; 周锦平; 付志恒; 周敏; 郭玉京; 潘同升; 林文玉
Original assignee: Delta Electronics Shanghai Co Ltd
Current assignee: Delta Electronics Shanghai Co Ltd
Priority date: 2018-11-02
Filing date: 2019-10-29
Publication date: 2021-10-26
Anticipated expiration: 2039-10-29
Also published as: CN113555196B; CN111145987B; CN111145987A

Abstract

The application provides a transformer module and a power module, wherein the transformer module comprises a first metal winding, the foil is wound on a magnetic core, the transformer module comprises a first section winding formed on a first wiring layer and a second section winding formed on a second wiring layer, the first end of the first section winding is electrically connected to a first pin through a first connecting piece, the second end of the first section winding is electrically connected to a second pin through a second connecting piece, the first connecting piece and the second connecting piece both penetrate through a first insulating layer, the first end of the second section winding forms a third pin, the first pin and the third pin are both positioned on the first surface of the transformer module, the second end of the second section winding forms a fourth pin, the second pin and the fourth pin are both positioned on the second surface of the transformer module, and further the loss of the pins is reduced, and the transformer module adopts a winding with a foil winding structure, so that the effect of uniform distribution of winding current is achieved.

Description

Transformer module and power module

The application is a division of patent application with application number 2019110359206, application date 2019, 10 and 29, and invention name "transformer module and power module".

The invention patent applications with application numbers of 2019110359206, application dates of 2019, 10 and 29 and invention names of "transformer module and power module" have priority to the invention patents with application numbers of 2018113011746, application dates of 2018, 11 and 02 and invention names of "transformer module and power module".

Technical Field

The application relates to the technical field of transformers, in particular to a transformer module and a power module.

Background

With the rise of the requirements of human beings on intelligent life, the demand of society on data processing is increasingly vigorous. Global energy consumption on data processing reaches hundreds of billions or even trillions per year on average; and the floor space of a large data center can reach tens of thousands of square meters. Therefore, high efficiency and high power density are key indicators for the healthy development of this industry.

The key Unit of the data center is a server, and a main board of the data center generally includes a Central Processing Unit (CPU), a chipset (Chipsets), a memory and other data Processing chips, and power supplies and necessary peripheral components of the chips. With the increase of the processing capacity of the server per unit volume, the number and the integration level of the processing chips are also increased, and the space occupation and the power consumption are increased. Therefore, the power supply for these chips (also called motherboard power supply) is expected to have higher efficiency, higher power density and smaller size to support the requirements of energy saving and reduced floor space of the whole server and even the whole data center because the power supply is on the same motherboard as the data processing chip. In order to meet the requirement of high power density, the switching frequency of the power supply is also higher and higher, and the switching frequency of the low-voltage high-current power supply in the industry is basically 1 Megahertz (MHz).

For a transformer applied to low voltage and large current, a multi-layer Printed Circuit Board (PCB) mode is mostly adopted for implementation, fig. 1 is a side view cross-sectional view of a transformer adopting a multi-layer PCB mode provided in the prior art, as shown in fig. 1, the PCB metal winding is a horizontal winding process, that is, a winding is a plane (winding layer) formed on the PCB, and the PCB is usually sleeved on a magnetic column, so that the magnetic column is perpendicular or nearly perpendicular to the PCB, and thus the magnetic column is perpendicular or nearly perpendicular to each winding wiring layer formed on the PCB. Among them, limited to forming windings in the wiring layer, assuming that a dimension (wiring thickness) of a metal winding formed in the wiring layer parallel to the longitudinal direction of the pillar is W, and a dimension (e.g., wiring width) of the metal winding perpendicular to the longitudinal direction of the pillar is H, in general, H and W satisfy the following relationship: h >10W, and this type of metal winding is commonly referred to as an edgewise metal winding. Even if the wiring layers which are parallel to each other are connected through the via hole, the wiring layers of the main wiring are perpendicular to the magnetic pillar, and the via hole is perpendicular to the wiring layers, so that the via hole is necessarily parallel to the magnetic pillar when the main wiring is vertically wound, and the single via hole hardly interlinks magnetic flux. The inner layer wiring layer is generally connected to the surface layer of the PCB through the through holes so as to connect the pins, the through holes are long in length and small in quantity when the inner layer wiring layer is vertically wound, and loss caused by the through holes is large. Meanwhile, assuming that the metal winding of the vertical winding structure is a ring in the horizontal direction, and the width of the ring is H, it can be seen that, for the ring formed by the metal winding, the impedances of the outer part far away from the magnetic pillar and the inner part close to the magnetic pillar are different due to the reasons of the difference in the circumferential lengths of the inner and outer rings, and thus the current distribution is uneven.

Fig. 2 is a schematic structural diagram of another transformer module provided in the prior art. For convenience of explanation, the shape of the winding and the positional relationship between the winding and the magnetic core are specifically drawn in the schematic diagram, but the present application is not limited thereto. As shown in fig. 2, a winding coated on the magnetic pillar is formed in any wiring layer, and the distances between different parts of the same turn of winding and the magnetic core are similar, that is, the equivalent diameters are similar, the equivalent impedances are similar, and the winding current distribution is uniform. If a plurality of wiring layers are required, an insulating layer and a new wiring layer can be sequentially added outside the wiring layers. With reference to fig. 2, a dimension W of the winding formed on the wiring layer in a direction parallel to the longitudinal direction of the magnetic pillar and a dimension H of the winding in a direction perpendicular to the magnetic pillar of the magnetic core are defined. When H and W satisfy the relationship: when W >10H, we define the winding mode as foil winding structure winding. In this configuration of the transformer, the pins, 21,22 in the figure, connecting the windings to external circuitry are typically routed from the sides of the windings. In this way, all the current on the winding flows through the pin, which not only causes the winding current to be unevenly distributed, but also causes significant losses on the pin. In addition, in the prior art transformer structure, the pins are typically relatively long, which further exacerbates the losses on the pins.

Disclosure of Invention

The application provides a transformer module and a power module, thereby achieving the purpose of uniform winding distribution. And reduces pin loss.

In a first aspect, the present application provides a transformer module comprising:

the magnetic core is provided with a first wiring layer, a first insulating layer and a second wiring layer from outside to inside in sequence;

the first metal winding is formed on the first wiring layer and wound on the magnetic core in a foil mode;

the first insulating layer is at least partially covered by the first metal winding;

the second metal winding is formed on the second wiring layer and wound on the magnetic core in a foil mode, wherein at least part of the second metal winding is covered by the first insulating layer, and at least part of the second metal winding is covered by the first metal winding;

the transformer module further comprises a first pin, a second pin, a third pin and a fourth pin, the first metal winding comprises a first end and a second end, the second metal winding comprises a first end and a second end, the first end and the second end of the first metal winding form the first pin and the second pin respectively, the first end and the second end of the second metal winding are electrically connected to the third pin and the fourth pin through a first connecting piece and a second connecting piece respectively, and the first connecting piece and the second connecting piece penetrate through the first insulating layer.

Optionally, the first connector and the second connector both pass through the first wiring layer.

Optionally, the first connecting member and the second connecting member are via holes.

Optionally, the second metal winding, the first connector, the second connector, and the third and fourth pins are an integral piece.

Optionally, the first connecting piece and the second connecting piece are formed by cutting the second metal winding, and the third pin and the fourth pin are formed by folding the first connecting piece and the second connecting piece respectively.

Optionally, the first pin, the second pin, the third pin, and the fourth pin are located on the first surface of the transformer module for connecting with an external circuit.

Optionally, a second insulating layer and a third wiring layer are further sequentially disposed on the magnetic core, and the second insulating layer is at least partially covered by the second metal winding;

the transformer module further includes:

the third metal winding is formed on the third wiring layer and wound on the magnetic core in a foil mode, wherein at least part of the third metal winding is covered by the second insulating layer; and

a fifth pin;

the third metal winding comprises a first end and a second end, the first end of the third metal winding is electrically connected with the fifth pin through a third connecting piece, and the second end of the third metal winding is electrically connected with the first pin.

Optionally, the third connection member is a via hole or is formed by cutting a third metal winding.

Alternatively, the first metal winding has one turn, the second metal winding has a plurality of turns to form a spiral-shaped winding around the magnetic core, and the third metal winding has one turn.

Optionally, the number of the fifth pins is plural, and the plural fifth pins are located between the first pin and the second pin.

Optionally, the second pins further include a plurality of teeth, and the plurality of teeth and the plurality of fifth pins are arranged in a staggered manner.

Optionally, there is one fifth pin, and the fifth pin is located between the first pin and the second pin.

Optionally, the magnetic core comprises a through hole, wherein, on the first face, the fifth pin is C-shaped or square-shaped surrounding the through hole, the first pin is C-shaped or square-shaped surrounding the through hole, and the second pin is C-shaped or square-shaped surrounding the through hole.

Optionally, 1/2 where the length of the first leg is greater than or equal to the length of the first metal winding; and/or the length of the second leg is greater than or equal to 1/2 the length of the first metal winding; and/or the length of the third pin is greater than or equal to 1/2 of the length of the second metal winding; and/or the length of the fourth pin is greater than or equal to 1/2 the length of the second metal winding; and/or the length of the fifth pin is greater than or equal to 1/2 the length of the third metal winding.

Optionally, the first leads are plural, and the total length of the plural first leads is greater than or equal to 1/2 of the length of the first metal winding; and/or the presence of a gas in the gas,

the second pins are plural, and the total length of the second pins is greater than or equal to 1/2 of the length of the first metal winding; and/or the presence of a gas in the gas,

the third pins are plural, and the total length of the plurality of third pins is greater than or equal to 1/2 of the length of the second metal winding; and/or the presence of a gas in the gas,

the number of the fourth pins is plural, and the total length of the plurality of the fourth pins is greater than or equal to 1/2 of the length of the second metal winding.

Optionally, the first insulating layer includes a base insulating layer and an auxiliary insulating layer.

Optionally, the insulating mode of the base insulating layer is an electro-deposition process; the auxiliary insulating layer is insulating glue which is locally arranged.

In a second aspect, the present application provides a power module comprising:

a transformer module as in the first aspect;

and the switch module is contacted with the first surface of the transformer module and is electrically connected with the first pin and the second pin.

Optionally, the switch module includes a carrier and at least one power switch, the power switch is disposed on the carrier, and the power switch is electrically connected to the first pin and/or the second pin.

Optionally, the power module further includes a capacitor module, the capacitor module is located on the carrier and disposed adjacent to the transformer module, and the capacitor module is electrically connected to the first pin. Or the capacitor module is positioned on the same side of the carrier plate and adjacent to the switch module; or the capacitor module is embedded in the carrier plate; or the capacitor module is positioned in the window of the transformer module; or the capacitor module is positioned on the upper surface of the magnetic core of the transformer module or the capacitor module is positioned below the power switch.

Optionally, a second insulating layer and a third wiring layer are further sequentially disposed on the magnetic core of the transformer module, and at least part of the second insulating layer is covered by the second metal winding;

the transformer module further includes:

the fifth pin is positioned on the first surface of the transformer module;

the third metal winding comprises a first end and a second end, the first end of the third metal winding is electrically connected with the fifth pin through a third connecting piece, and the second end of the third metal winding is electrically connected with the first pin;

the switch module is also electrically connected with the fifth pin.

Optionally, the power module further includes a first power switch and a second power switch, wherein the first end of the first power switch is electrically connected to the second pin, the first end of the second power switch is electrically connected to the fifth pin, and the second end of the first power switch is electrically connected to the second end of the second power switch.

Optionally, the switch module includes a plurality of first power switches connected in parallel and a plurality of second power switches connected in parallel, and the plurality of first power switches and the plurality of second power switches are arranged in two rows separately, wherein first ends of the plurality of first power switches are electrically connected to the second pin, first ends of the plurality of second power switches are electrically connected to the fifth pin, and second ends of the plurality of first power switches are electrically connected to second ends of the plurality of second power switches.

In a third aspect, the present application provides a transformer module comprising:

the magnetic core is provided with a first wiring layer, a first insulating layer and a second wiring layer from inside to outside in sequence;

the first metal winding is wound on the magnetic core in a foil mode and comprises a first section of winding formed on the first wiring layer and a second section of winding formed on the second wiring layer, the first end of the first section of winding is electrically connected to the first pin through a first connecting piece, the second end of the first section of winding is electrically connected to the second pin through a second connecting piece, the first connecting piece and the second connecting piece penetrate through the first insulating layer, the first end of the second section of winding forms a third pin, the first pin and the third pin are located on the first surface of the transformer module, the second end of the second section of winding forms a fourth pin, and the second pin and the fourth pin are located on the second surface of the transformer module;

the second metal winding is wound on the magnetic core in a foil mode and comprises a third section of winding formed on the first wiring layer and a fourth section of winding formed on the second wiring layer, the first end of the third section of winding is connected to the fifth pin through a third connecting piece, the second end of the third section of winding is connected to the second pin through a fourth connecting piece, the third connecting piece and the fourth connecting piece penetrate through the first insulating layer, the first end of the fourth section of winding forms a sixth pin, the second end of the fourth section of winding is electrically connected to the fourth pin, and the fifth pin and the sixth pin are located on the same face of the transformer module.

Optionally, at least one of the first connecting piece, the second connecting piece, the third connecting piece, and the fourth connecting piece is a via hole or a metal winding connected to the connecting piece is an integrated piece, and the metal winding is cut and folded by the metal winding.

Optionally, a third wiring layer and a second insulating layer are further disposed on the magnetic core, wherein the third wiring layer and the second insulating layer are sequentially located between the first insulating layer and the second wiring layer; and

and a second metal winding, foil-wound on the magnetic core, on the third wiring layer.

Alternatively, the first metal winding has one turn, the third metal winding has a plurality of turns to form a spiral-shaped winding around the magnetic core, and the second metal winding has one turn.

Optionally, the first pins are plural, the fifth pins are plural, the plural first pins and the fifth pins are arranged in a staggered manner, and the plural first pins and the plural fifth pins are located between the third pins and the sixth pins.

Optionally, on the first surface, the first pin is C-shaped or square-shaped, the fifth pin is C-shaped or square-shaped, and both the first pin and the fifth pin are located between the third pin of the C-shaped or square-shaped and the sixth pin of the C-shaped or square-shaped.

Optionally, on the second face, the second pin is surrounded by the fourth pin.

Optionally, the first and second faces of the transformer module are opposing faces.

Optionally, 1/2 where the length of the first leg is greater than or equal to the length of the first metal winding; and/or the length of the second leg is greater than or equal to 1/2 the length of the first metal winding; and/or the length of the third leg is greater than or equal to 1/2 the length of the first metal winding; and/or the length of the fourth pin is greater than or equal to 1/2 the length of the first metal winding; and/or the length of the fifth pin is greater than or equal to 1/2 of the length of the second metal winding; and/or the length of the sixth pin is greater than or equal to 1/2 the length of the second metal winding.

the third pins are plural, and the total length of the plural third pins is greater than or equal to 1/2 of the length of the first metal winding; and/or the presence of a gas in the gas,

the total length of the plurality of fourth pins is greater than or equal to 1/2 the length of the first metal winding; and/or the presence of a gas in the gas,

the total length of the plurality of fifth pins is greater than or equal to 1/2 the length of the second metal winding; and/or the presence of a gas in the gas,

the sixth pins are plural, and the total length of the plural sixth pins is greater than or equal to 1/2 of the length of the second metal winding.

In a fourth aspect, the present application provides a power module comprising:

a transformer module as in the third aspect;

and the switch module is contacted with the first surface of the transformer module.

Optionally, the power module further comprises:

and the capacitor module is in contact with the second surface of the transformer module and is electrically connected with the second pin and the fourth pin.

Optionally, the switch module is electrically connected to the first pin, the third pin, the fifth pin, and the sixth pin.

Optionally, the switch module includes a plurality of first power switches and a plurality of second power switches, and the plurality of first power switches and the plurality of second power switches are arranged in two separate rows.

Optionally, the switch module includes a plurality of first power switches and a plurality of second power switches, the plurality of first power switches and the plurality of second power switches are disposed on the first surface of the transformer module, the plurality of first power switches are electrically connected to the first pin and the third pin, and the plurality of second power switches are electrically connected to the fifth pin and the sixth pin.

In a fifth aspect, the present application provides a transformer module comprising:

the first metal winding is wound on the magnetic core in a foil mode and comprises a first section of winding formed on the first wiring layer and a second section of winding formed on the second wiring layer, the first end of the first section of winding is electrically connected to the first end of the second section of winding through a first connecting piece, the second end of the first section of winding is electrically connected to the first pin through a second connecting piece, the second end of the second section of winding is connected to the second pin, and the first connecting piece and the second connecting piece penetrate through the first insulating layer;

and the second metal winding is wound on the magnetic core in a foil mode and comprises a third section of winding formed on the first wiring layer and a fourth section of winding formed on the second wiring layer, the first end of the third section of winding is connected to the first end of the fourth section of winding through a third connecting piece, the second end of the fourth section of winding forms a third pin, and the third connecting piece penetrates through the first insulating layer.

Optionally, the second end of the third segment of winding is electrically connected to the first pin, and the transformer module further includes a third metal winding.

Optionally, the first pin, the second pin, and the third pin are all located on the first surface of the transformer module.

Optionally, a second insulating layer and a third wiring layer are further disposed on the magnetic core, wherein the third wiring layer and the second insulating layer are sequentially located between the first insulating layer and the second wiring layer; and

and a third metal winding, foil-wound on the magnetic core, on the third wiring layer.

Optionally, the third pins are plural, the second pin further includes plural teeth, and the plural teeth and the plural third pins are arranged in a staggered manner.

Optionally, the second and third leads are all plural, and the plural second leads and the plural third leads are arranged in a staggered manner.

Optionally, the magnetic core includes a through hole, wherein the first pin, the second pin and the third pin are all in a C shape or a square shape surrounding the through hole, and the first pin is located between the second pin and the third pin.

Optionally, the magnetic core includes a through hole, and the first, second, and third pins are all plural, wherein the plural first pins, the plural second pins, and the plural third pins are all arranged around the through hole, and the plural first pins are located between the plural second pins and the plural third pins.

Optionally, 1/2 where the length of the first leg is greater than or equal to the length of the first metal winding; and/or the length of the second leg is greater than or equal to 1/2 the length of the first metal winding; and/or the length of the third leg is greater than or equal to 1/2 the length of the first metal winding.

the third pins are plural, and the total length of the plural third pins is greater than or equal to 1/2 of the length of the first metal winding

In a sixth aspect, the present application provides a power module comprising:

a transformer module of the fifth aspect, wherein the first pin, the second pin, and the third pin are all located on the first surface of the transformer module;

Optionally, the power module further comprises:

the capacitor module is positioned on the carrier plate and is arranged close to the transformer module, and the capacitor module is electrically connected with the first pin or the second pin; or the capacitor module is positioned on the same side of the carrier plate and adjacent to the switch module; or the capacitor module is embedded in the carrier plate; or the capacitance module is positioned in a window of the transformer module; or the capacitor module is positioned on the upper surface of the transformer module; or the capacitance module is positioned below the power switch.

Optionally, the switch module includes a plurality of first power switches connected in parallel and a plurality of second power switches connected in parallel, and the plurality of first power switches and the plurality of second power switches are arranged in two separate rows.

In a seventh aspect, the present application further provides a method for manufacturing a metal winding in a transformer module, including: cutting the first metal foil to form a connecting piece and a pin; performing insulation treatment on the surface of at least one of the first metal foil and the second metal foil; bending the first metal foil to form a first metal winding, and coating the first metal winding on the magnetic core; and at least partially coating a second metal foil on the surface of the first metal winding to form a second metal winding, wherein the pin of the first metal winding passes through the second metal winding.

Optionally, insulating the surface of at least one of the first metal foil and the second metal foil, including: carrying out first insulation treatment on the surface of the metal foil to form an inner base insulation layer; and performing second insulation treatment on the surface of the metal foil forming the base insulation layer to form an outer auxiliary insulation layer.

Optionally, the insulating manner of the base insulating layer is an electrodeposition process.

Optionally, the auxiliary insulating layer is a partially disposed insulating glue.

Optionally, before performing an insulation treatment on a surface of at least one of the first metal foil and the second metal foil, the method further includes: and roughening the surface of at least one metal foil.

Optionally, after performing an insulation treatment on a surface of at least one of the first metal foil and the second metal foil, the method further includes: coating the surface adhesive layer of at least one metal foil.

Optionally, the second metal winding is wound on the surface of the first metal winding, and a via hole or a gap is formed in the winding process to allow the pin of the first metal winding to pass through.

Optionally, the third metal foil is cut to form a via hole or a gap, the third metal foil is bent and coated on the surface of the second metal winding to form a third metal winding, and the pin of the first metal winding passes through the via hole or the gap.

The application provides a transformer module and power module, wherein the transformer module includes: a magnetic core, a first metal winding and a second metal winding. A first wiring layer, a first insulating layer and a second wiring layer are sequentially formed on the magnetic core from outside to inside; the first metal winding is formed on the first wiring layer and wound on the magnetic core in a foil mode; the first insulating layer is at least partially covered by the first metal winding; the second metal winding is formed on the second wiring layer and wound on the magnetic core in a foil mode, wherein the second metal winding is at least partially covered by the first insulating layer and at least partially covered by the first metal winding; the transformer module further comprises a first pin, a second pin, a third pin and a fourth pin, the first metal winding comprises a first end and a second end, the second metal winding comprises a first end and a second end, the first pin, the second pin, the third pin and the fourth pin are all located on the first surface of the transformer module and used for being connected with an external circuit, the first end and the second end of the first metal winding form the first pin and the second pin respectively, the first end and the second end of the second metal winding are electrically connected to the third pin and the fourth pin through a first connecting piece and a second connecting piece respectively, and the first connecting piece and the second connecting piece both penetrate through the first insulating layer.

Because the transformer winding cladding of foil winding structure is on the transformer magnetic pole for this foil winding structure winding part equivalent diameter is close, and equivalent impedance is close, thereby reaches the even effect of winding current distribution, can reduce the loss of pin through the mode of setting up of this application pin in addition.

Drawings

FIG. 1 is a side cross-sectional view of a transformer using a multi-layer PCB according to the prior art;

fig. 2 is a schematic structural diagram of another transformer module provided in the prior art;

fig. 3A is a perspective view of a magnetic core in a transformer module according to an embodiment of the present application;

FIG. 3B is a perspective view of the magnetic core of FIG. 3A after a second metal winding has been formed;

FIG. 3C is a perspective view of the module of FIG. 3B after forming a first metal winding;

fig. 3D is a perspective view of a transformer module according to an embodiment of the present application;

FIG. 3E is an electrical schematic of the terminals of the transformer module shown in FIG. 3C;

FIG. 3F is a perspective view of the winding edge of FIG. 3C with two integral pins;

FIG. 3G is a diagram illustrating a relationship between a ratio n of a pin size to a winding size and a winding loss P;

FIG. 3H is a perspective view of the winding edge of FIG. 3C having a plurality of leads;

FIG. 4A is a bottom view of the transformer module after forming a third metal winding;

fig. 4B is a bottom view of a transformer module according to an embodiment of the present application;

FIG. 4C is an electrical schematic of the terminals of the transformer module shown in FIG. 4B;

fig. 5 is a bottom view of another transformer module provided in an embodiment of the present application;

fig. 6A and fig. 6B are electrical schematic diagrams of end points of a power module according to an embodiment of the present disclosure;

fig. 6C and 6D are cross-sectional views of a power module according to an embodiment of the present application;

fig. 6E is a bottom view of a switch module according to an embodiment of the present application;

fig. 6F is a cross-sectional view of a power module according to an embodiment of the present application;

fig. 7 is an electrical schematic diagram of terminals of a power module according to an embodiment of the present disclosure;

FIG. 8 is a cross-sectional view of a transformer module taken along line AA' of FIG. 5 in an embodiment of the present application;

FIG. 9A is a cross-sectional view of a transformer winding according to an embodiment of the present application;

FIG. 9B is a cross-sectional view of a transformer winding according to an embodiment of the present application;

FIG. 9C is a bottom view of a transformer according to an embodiment of the present application;

FIG. 9D is a bottom view of a transformer according to an embodiment of the present application;

FIG. 9E is a schematic diagram of a portion of the transformer and the switching elements disposed thereon, shown in phantom in FIG. 9C;

FIG. 9F is a cross-sectional view of a power module according to an embodiment of the present application;

FIG. 10A is a cross-sectional view of a transformer according to an embodiment of the present application;

FIG. 10B is a plan view of the windings of one embodiment of the present application after deployment;

FIG. 10C is a perspective view of a winding in an embodiment of the present application;

FIG. 10D is a perspective view of a winding in an embodiment of the present application;

FIG. 10E is a perspective view of a winding in an embodiment of the present application;

FIG. 10F is a perspective view of a winding in an embodiment of the present application;

fig. 10G is a schematic diagram of a pin arrangement according to an embodiment of the present application;

FIG. 10B-1 is a schematic cross-sectional view of a metal layer and an insulating layer;

FIG. 10B-2 is a schematic cross-sectional view of the metal layer before bending;

FIG. 10B-3 is a schematic cross-sectional view of the metal layer after bending;

FIG. 10B-4 is a flow chart of the manufacture of a metal winding;

fig. 11A and fig. 11B are respectively schematic structural diagrams of a transformer module according to an embodiment of the present application;

fig. 12A is a cross-sectional view of a transformer module taken along line AB shown in fig. 11A according to an embodiment of the present application;

fig. 12B is a cross-sectional view of a transformer module taken along line AB shown in fig. 11B according to an embodiment of the present application;

fig. 13A is a top view of a transformer module according to an embodiment of the present application;

fig. 13B is a top view of a transformer module according to another embodiment of the present application;

fig. 14A is a bottom view of a transformer module according to an embodiment of the present application;

fig. 14B is a bottom view of a transformer module according to another embodiment of the present application;

FIG. 15 is a cross-sectional view of a power module provided in accordance with another embodiment of the present application;

fig. 16 is a top view of a power module according to another embodiment of the present application.

Detailed Description

For a transformer applied by low voltage and large current, in the prior art, a winding mostly adopts a vertical winding structure realized by a plurality of layers of PCBs, at the moment, the plane of a PCB is perpendicular to a magnetic column, and the winding surrounding the magnetic column is formed by routing on a PCB wiring layer. However, the vertical winding structure will cause the inner equivalent diameter and the outer equivalent diameter of the metal winding wire to be inconsistent, and cause the inner equivalent impedance of the winding to be smaller than the outer equivalent impedance of the winding, so that the problem of non-uniform current distribution of the winding exists, and the winding loss is larger.

In addition, another prior art configuration employs a winding foil configuration in which the windings are substantially equidistant from the core, as shown in FIG. 2, i.e., the radii R of the portions of the windings_1B,R_2BBasicAnd so the current distribution of the winding parts is more uniform compared to the transformer of PCB structure. However, in this structure, the winding outlet is usually led out from the side of the winding, and therefore the current distribution of the winding near the outlet is not uniform, and this problem is more serious particularly when the winding width W is wide; in addition, the egress end is usually longer in length, and therefore the loss of the egress end is also larger. In order to solve the above technical problem, the present application provides a transformer module and a power module.

In one embodiment of the invention, the windings are formed in the wiring layer by, for example, electroplating, electroless plating, spraying, dipping, electrophoresis, electrostatic spraying, chemical vapor deposition, physical vapor deposition, evaporation, or printing. The surface of the magnetic member can be provided with a plurality of wiring layers, insulating layers are arranged among the wiring layers, and windings among different wiring layers can be connected through connecting pieces such as through holes penetrating through the insulating layers.

Example one

Fig. 3A is a perspective view of a magnetic core in a transformer module according to an embodiment of the present application, fig. 3B is a perspective view of the magnetic core shown in fig. 3A after a second metal winding is formed on the magnetic core, fig. 3C is a perspective view of the module shown in fig. 3B after a first metal winding is formed on the module (bottom surface is upward), fig. 3D is a perspective view of a transformer module according to an embodiment of the present application, and fig. 3E is an electrical schematic diagram of each terminal (e.g., pin) of the transformer module shown in fig. 3D, which is described with reference to fig. 3A to 3E, and the transformer module includes: a magnetic core 31, a first metal winding 33 (e.g., as the secondary winding S2 of the transformer module, as shown in fig. 3E), and a second metal winding 32 (e.g., as the primary winding P of the transformer module, as shown in fig. 3E).

Optionally, the magnetic core is square, annular, I-shaped or C-shaped. For example: the core 31 shown in fig. 3A is a square core. The shape of the magnetic core is not limited by the present application.

Optionally, the number of turns of the first metal winding (secondary winding S2) is one or more, for example: the number of turns of the first metal winding 33 shown in fig. 3C is one turn.

Optionally, the number of turns of the second metal winding (primary winding P) is one or more. As shown in fig. 3B, the second metal winding 32 has a plurality of turns to form a spiral winding around the plurality of legs of the square core, wherein the black thick bar shown in fig. 3B is an exposed insulating layer between the turns of the metal winding.

Specifically, a first wiring layer, a first insulating layer and a second wiring layer are sequentially arranged on the magnetic core from outside to inside. As shown in fig. 3B, the metal of the second wiring layer may be formed into the second metal winding 32 by etching or the like, so that the second metal winding 32 is foil-wound around the magnetic core 31. After the second metal winding 32 is formed to cover the magnetic core 31, a first insulating layer may be disposed outside the second wiring layer, and a first wiring layer may be disposed outside the first insulating layer, so that the second metal winding is at least partially covered by the first insulating layer and at least partially covered by the first wiring layer. As shown in fig. 3C, a first metal winding 33 may be formed on the first wiring layer, and the first metal winding 33 is foil-wound around the magnetic core 31. The first metal winding 33 is wrapped around the magnetic core 31 and also wrapped around the second metal winding 32. Thus, the second metal winding is also at least partially covered by the first metal winding, and the first insulating layer is also at least partially covered by the first metal winding. The coverage described in this application may be a contact coverage, or a non-contact coverage, such as: and (4) covering the projection. As described above, "covering" in "the first insulating layer is at least partially covered with the first metal winding" refers to covering in contact. The "covering" in "the second metal winding is at least partially covered with the first insulating layer" also refers to a covering of a contact type. The "covering" in "the second metal winding is at least partially covered by the first metal winding" refers to a non-contact covering, i.e., a projected covering.

Specifically, in an embodiment, an initial insulating layer may be selectively attached to the surface of the magnetic core by spraying or depositing, and the base insulating layer has the functions of enhancing the bonding force and protecting the magnetic core, but the invention is not limited thereto, and the base insulating layer may not be provided; arranging a second wiring layer on the surface in a manner of electroplating or chemical plating and the like, wherein the second wiring layer can be a copper layer; electroplating or chemically plating a metal protection layer such as a tin layer or a gold layer on the surface of the second wiring layer; then, carrying out pattern definition on the metal protection layer through a direct-write protection process, and exposing a part of second wiring layer to be etched; etching the second wiring layer pattern under the protection of the metal protection layer; and finally, removing the protective layer to form a second metal winding serving as a primary winding P. Then selectively attaching a first insulating layer on the second metal winding in a spraying or depositing mode and the like, wherein the first insulating layer has the functions of enhancing the binding force and protecting the magnetic core; arranging a first wiring layer on the surface in an electroplating or chemical plating mode, wherein the first wiring layer can be a copper layer; electroplating or chemically plating a metal protection layer such as a tin layer or a gold layer on the surface of the first wiring layer; then, carrying out pattern definition on the metal protection layer through a direct-write protection process, and exposing a part of the first wiring layer to be etched; etching the first wiring layer pattern under the protection of the metal protection layer; finally, the protective layer is removed, and the first metal winding is formed, i.e., as the secondary winding S2. However, the invention is not limited thereto, and other winding forming processes may be applied.

In this embodiment, it can be seen that the second metal winding 32 is a spiral winding with a plurality of turns around a plurality of magnetic poles of the square magnetic core. The first metal winding 33 has one turn, and wraps the plurality of legs of the square-shaped magnetic core, and both ends (331 and 332) of the single-turn winding are formed only in the square-shaped slits formed in the bottom surface of the magnetic core by etching, cutting, or the like, as shown in fig. 3C.

Further, as described with reference to fig. 3B to 3E, in the present embodiment, the two ends of the first metal winding 33 include a first end 331 and a second end 332 (as shown in fig. 3C), and a first pin V0 and a second pin D2 (as shown in fig. 3D) are respectively formed on the outer surface of the transformer module. The second metal winding 32 also has a first end and a second end, but since the first end and the second end of the second metal winding 32 are covered by an insulating layer or the like, the third pin P1 and the fourth pin P2 (as shown in fig. 3D) need to be connected to the outer layer through connectors, such as a first via and a second via (not shown), respectively, for electrical connection with an external circuit, the connectors, i.e., the first via and the second via, each passing through at least the first insulating layer. The first metal winding 33 is, for example, a secondary winding, and the second metal winding 32 is, for example, a primary winding. For connection with an external switch circuit, a connection region corresponding to the SR may be additionally provided, but the present application is not limited thereto.

The transformer module is connected to an external circuit (e.g., a switch module) through the first pin V0, the second pin D2, the third pin P1, and the fourth pin P2 (as shown in fig. 3E), and the first pin V0, the second pin D2, the third pin P1, and the fourth pin P2 are located on a first surface (e.g., a bottom surface) of the transformer module. In this embodiment, the first surface of the transformer module is located on the outer surface of the first metal winding, or the first surface is closer to the outer surface of the first metal winding, for example, the distance is not more than 1 mm, so that the pins of the whole module located on the first surface are almost located on the same horizontal plane, which facilitates external assembly and connection. However, the invention is not limited thereto.

The first pin V0, the second pin D2, the third pin P1 or the fourth pin P2 may be square or circular in shape.

Optionally, the first pin V0, the second pin D2, the third pin P1 and the fourth pin P2 in the above embodiments may not be located on the same plane of the transformer module, such as: the first and second pins V0 and D2 may be located at a first side of the transformer module, and the third and fourth pins P1 and P2 may be located at a second side of the transformer module, wherein the first and second sides are different sides.

It should be noted that, in the prior art, because the radiuses of different portions of the same layer of winding of the transformer with the multi-layer PCB winding structure are different, the impedance of the inner ring of the same layer of winding is smaller than that of the outer ring of the same layer of winding, so that the current distribution on the same layer of winding is not uniform, and accordingly, the loss of the winding is large. In addition, for the technology of implementing vias, the inner layer windings of the multilayer PCB winding need to be connected to the surface layer through vias, but the apertures of the vias are large, usually larger than 150 microns, and the spacing between vias is usually larger than 150 microns due to the structural and wiring pattern definition. In this embodiment, because the rigid PCB is not provided, the first via hole and the second via hole may be directly formed on the first insulating layer by laser drilling, so that the diameters of the first via hole and the second via hole are smaller, and the space utilization rate of the transformer module may be further improved. However, the invention is not limited thereto.

Furthermore, through the adjustment of electroplating agents, a better electroplating filling rate can be achieved, and even copper layers can be filled in the first via hole and the second via hole, so that the purpose of reducing winding loss is achieved.

Further, as mentioned above, the prior art generally employs a multi-layer PCB metal winding parallel connection manner. Especially in the application of low-voltage large-current output, when a multilayer PCB winding structure is adopted, the number of layers of the PCB is usually large, for example, in the application of a server main board power supply, the number of layers of the PCB winding is about 10, and the inner winding of the multilayer PCB winding needs to be connected to the surface layer through a via hole. The via hole is long, the impedance is high, and the winding loss caused by the via hole is large. In some embodiments of the present application, since the thickness of the insulating layer, such as the first insulating layer, is usually less than or equal to 200 micrometers and is relatively thin, the first via and/or the second via are relatively short and have low impedance, so that the first via and the second via can reduce loss of the winding.

In addition, for the prior art of another transformer with a foil winding structure, although the winding adopts the foil winding structure, the radii of all parts of the winding in the same layer are basically equal, that is, the current distribution is uniform, but the pin at the winding outlet end is led out from the side surface of the winding. This also makes the winding current distribution near the outlet end less uniform. In addition, the length of the pin is long, and accordingly, the loss on the pin is also large.

Based on this, the present embodiment provides a transformer module, which not only uses the winding with foil winding structure to achieve the effect of more uniform current distribution on the winding, but also the output end of the inner winding is connected to the pin of the transformer module through the insulating layer and/or the outer wiring layer at least partially covering the inner winding through a connecting component, such as a via hole, and the projection of the pin is at least partially located in each wiring layer. This configuration greatly reduces the pin length and winding current maldistribution conditions caused by the pins. In addition, as seen in fig. 3D, the second pin D2 and the first pin V0 almost cover the four magnetic columns on the upper surface of the transformer, and this distributed pin structure further improves the uniformity of current distribution on the winding, so that the winding loss is greatly reduced.

As shown in fig. 3C and 3D, the first metal winding is a layer of copper foil continuously wrapped around the magnetic core, the winding wraps four core legs, two ends of the winding are respectively connected to two pins V0 and a D2, the two pins are connected to an external circuit such as a switching device, and the like, wherein the number of the pins V0 and D2 is one, as shown in fig. 3D. The structure shown in fig. 3F is slightly different from that of 3D. In fig. 3F, the metal winding is continuously wound around a portion of the legs, e.g., three legs, of the square-shaped core. The two ends of the winding are still connected to two pins V0 and D2, respectively, and the number of the pins V0 and D2 is also one. Taking fig. 3F as an example, when viewed from one plane of the transformer, a is the inner length of the winding, and b is the outer length of the winding, so that the average length W of the winding is (a + b)/2, d is the average length of the pins on the winding, n is the ratio of the pin size to the winding size, and n is d/W. Since the winding is connected to an external circuit through the pins, the magnitude of d will affect the uniformity of the current distribution on the winding with respect to the average length of the winding. For a certain average length of the winding, as d increases, the current distribution becomes more and more uniform, and the winding loss becomes smaller and smaller. As shown in fig. 3G, the abscissa in fig. 3G is n, and the ordinate P is the winding loss, and it can be seen from the figure that as n increases, the corresponding winding loss decreases greatly. Preferably, when d is larger than or equal to 1/2W, the winding loss is smaller and the stability is facilitated. In fig. 3D, n is 1, that is, the length of the pin is almost the average length of the winding, so the pin structure in fig. 3D can make the current distribution uniformity on the winding better, and accordingly the winding loss is smaller. The magnetic core is not limited to the square shape and is also suitable for magnetic cores of T type, UU type, UI type and the like.

Similarly, the pins of the secondary winding may be a plurality of pins, as shown in fig. 3H, and the structures of fig. 3H and fig. 3F are substantially the same, and both include a square magnetic core covered with a continuous winding wound around three magnetic columns. Unlike fig. 3F, one winding in fig. 3H includes a plurality of first pins V0 and a plurality of second pins D2, i.e., the number of the first pins V0 and the number of the second pins D2 are both greater than or equal to 2. As shown in fig. 3H, the pin length includes three parameters: d1, d2 and d3, and the total pin length d is d1+ d2+ d 3. In fig. 3H, if V0 or D2 is only a single pin, the corresponding winding loss is still not small because the length of the V0 or D2 pin is small, i.e., the ratio n of the pin length to the average winding length is small. When V0 or D2 is a plurality of pins, such as three pins as shown in the figure, the pin length is greatly increased, and the ratio n of the pin length to the average winding length is increased, so that the current distribution on the winding is more uniform. It is understood that the leads V0 and D2 may be square or circular in shape, for example, when the leads are circular, the length of the leads may be the diameter of a circle. Further, the more uniform the distribution of the plurality of first pins V0 and the plurality of second pins D2, the more uniform the current distribution in the winding, and accordingly, the smaller the winding loss. In general, preferably, when the total length D of the first pin V0 or the second pin D2 is greater than or equal to 1/2 the winding length W, the winding loss is small and tends to be stable; the more the number of the first pins V0 or the second pins D2 is, the smaller the winding loss is; the more uniformly the first pin V0 or the second pin D2 is distributed, the smaller the winding loss.

In this embodiment 3C-3D, only one illustration of a foil wound transformer module is shown, i.e. the foil wound structural winding wraps around the four legs of the magnetic core. In fact, the foil-wound structure winding may cover one magnetic pillar or a plurality of magnetic pillars. This is not limited by the present application.

Furthermore, the power of the transformer module provided by the embodiment of the application is easy to expand, and the magnetic columns can be completely wrapped by the winding so as to improve the power of the transformer module; the power of the transformer module can also be increased by lengthening the magnetic pole and widening the winding at the same time.

Example two

On the basis of the first embodiment, a second embodiment of the present application further provides a transformer module, where a second insulating layer and a third wiring layer are sequentially disposed in the second wiring layer on the magnetic core of the transformer module, so that the second insulating layer is at least partially covered by the second metal winding.

The transformer module further includes: the third metal winding is formed on the third wiring layer and wound on the magnetic core in a foil mode, and at least part of the third metal winding is covered by the second insulating layer; and a fifth pin, which is located on the first surface of the transformer module and is used for electrically connecting the covered third metal winding.

Specifically, fig. 4A is a bottom view of the transformer module after the third metal winding is formed, fig. 4B is a bottom view of the transformer module according to an embodiment of the present disclosure, and fig. 4C is an electrical schematic diagram of each end point of the transformer module shown in fig. 4B. As explained with reference to fig. 4A to 4C, unlike the embodiment shown in fig. 3A to 3E, the present embodiment further provides a third wiring layer, that is, a first wiring layer, a first insulating layer, a second wiring layer, a second insulating layer, and a third wiring layer from the outside to the inside, where the first wiring layer, the second wiring layer, and the third wiring layer are used to form a first metal winding, a second metal winding, and a third metal winding, respectively. The second metal winding can be used as a primary winding P, the first metal winding can be used as a secondary winding S2, and the third metal winding can be used as a secondary winding S1, so that a sandwich structure that the secondary winding clamps the primary winding is formed. The third metal winding 34 is, for example, one turn, and as shown in fig. 4A, the third metal winding 34 wraps a plurality of magnetic columns of the square magnetic core, and a square slit is formed only on the bottom surface of the magnetic core by etching, cutting, or the like, to form both ends (for example, 341 and 342) of the single turn winding.

A second insulating layer, a second wiring layer, a first insulating layer, a first wiring layer, and the like are provided outside the third wiring layer, so that the third metal winding is at least partially covered with the second insulating layer. The two ends of the third metal winding 34 include a first end 341 and a second end 342 (as shown in fig. 4A), the first end (e.g., D1) of the third metal winding 34 is connected to the outermost fifth pin D1 through a third via (not shown) for electrically connecting with an external circuit, the third via passes through the first and second insulating layers and the second wiring layer, wherein the fifth pin D1 may also be located on the first surface (e.g., the bottom surface). A second end (e.g., V0) of the third metal winding 34 is commonly connected to one end of the first wiring layer winding, and is commonly connected to the first pin V0 through a fourth via (not shown), which is not limited by the invention. The connection modes of the first metal winding and the second metal winding with the external pin may be the same as the previous embodiment, the first metal winding is connected to the first pin V0 and the second pin D2, and the second metal winding is connected to the third pin P1 and the fourth pin P2, which is not described again.

Specifically, a base insulating layer is selectively attached to the surface of the magnetic core by spraying or depositing, and the base insulating layer plays roles of insulating, enhancing the bonding force, protecting the magnetic core, and the like, but the invention is not limited thereto, and the base insulating layer may not be provided; sequentially arranging a third wiring layer, such as a copper layer, on the surface in an electroplating or chemical plating mode; thirdly, electroplating or chemically plating a metal protection layer such as a tin layer or a gold layer on the surface of the third wiring layer; then, carrying out pattern definition on the metal protective layer through a direct-write protection process, and exposing a part of a third wiring layer to be etched; etching the third wiring layer pattern under the protection of the protective layer; finally, removing the protective layer to form a third metal winding, namely a secondary winding S1, and then attaching a second insulating layer on the third metal winding by spraying or depositing and the like; arranging a second wiring layer on the surface in an electroplating or chemical plating mode, wherein the second wiring layer can be a copper layer; electroplating or chemically plating a metal protection layer such as a tin layer or a gold layer on the surface of the second wiring layer; then, carrying out figure definition on the metal protection layer through a direct-write protection process, and exposing a part of second wiring layer to be etched; etching the second wiring layer pattern under the protection of the metal protection layer; and finally, removing the protective layer to form a second metal winding, namely the primary winding P. Then, a first insulating layer is attached to the second metal winding in a spraying or depositing mode; arranging a first wiring layer on the surface in an electroplating or chemical plating mode, wherein the first wiring layer can be a copper layer; electroplating or chemically plating a metal protection layer such as a tin layer or a gold layer on the surface of the first wiring layer; then, carrying out pattern definition on the metal protection layer through a direct-write protection process, and exposing a part of the first wiring layer to be etched; etching the first wiring layer pattern under the protection of the metal protection layer; finally, the protective layer is removed, and the first metal winding, i.e., the secondary winding S2, is formed. However, the invention is not limited thereto, and other winding forming processes may be applied.

Alternatively, as shown in fig. 4B, the number of the fifth pins D1 is plural, and the plural fifth pins D1 are located between the first pin V0 and the second pin D2. Further, the second lead D2 further includes a plurality of teeth 41, and the plurality of teeth 41 and the plurality of fifth surface-mount D1 leads are arranged in a staggered manner. Optionally, the plurality of teeth 41 and the plurality of fifth surface-mount D1 pins are uniformly staggered. The use of the fifth surface-mount pins and the second pins can help to distribute the current uniformly, and can be used to connect multiple external devices, which helps to reduce impedance and improve integration, for example, as shown in fig. 15, can be used to connect multiple switch modules. Alternatively, the leads may be cylindrical or spherical, and the invention is not limited thereto.

Alternatively, fig. 5 is a bottom view of another transformer module according to an embodiment of the present application, and as shown in fig. 5, there is one fifth pin D1, and the fifth pin D1 is located between the first pin V0 and the second pin D2. The magnetic core may include a through hole 61, and the fifth lead D1 is partially surrounded by the through hole 61, for example, in a C-shape, the first lead V0 is a C-shape surrounding the through hole 61, and the second lead D2 is a C-shape partially surrounding the through hole 61, as viewed from the bottom surface of the transformer module. However, the present invention is not limited thereto, and the first, second and fifth leads may have other shapes such as a square shape surrounding the through hole by adjusting the positions of the third lead P1 and the fourth lead P2. The shape of C-shape, square shape, etc. can increase the connecting strength with the external module, and is suitable for connecting a plurality of modules.

EXAMPLE III

Fig. 6A and 6B are electrical schematic diagrams of respective end points of a power module according to an embodiment of the present disclosure, and fig. 6C and 6D are cross-sectional views of a power module according to an embodiment of the present disclosure, which are described with reference to fig. 6A to 6D, respectively, and the power module includes:

a transformer module 71 as in the various embodiments of the present application.

And the switch module 72 is in contact with a first surface (e.g., a bottom surface with pins) of the transformer module 71 and is electrically connected with the first pin V0 and the second pin D2.

Optionally, the switch module 72 includes a carrier 74 and at least one power switch 73, as shown in fig. 6A and 6C, the switch module 72 includes at least one power switch 73, and the power switch 73 is electrically connected to the first pin V0; as shown in fig. 6B and 6D, in another embodiment, the switch module may also include at least one full bridge circuit, the full bridge circuit is formed by at least four power switches (e.g., MOSFETs) interconnected, and the power switches are disposed on the carrier board 74 and electrically connected to the first pin V0 and the second pin D2. Different types of power switches may be selectively electrically connected to the first pin V0 and/or the second pin D2 according to the actual application of the circuit topology, but the invention is not limited thereto, and the power switches may be connected to other pins, and each power switch shown in the figure may be connected in parallel by a plurality of power switches according to the output power selection of the actual transformer. As shown in fig. 6C and 6D, the power switches may be both located on the lower surface of the transformer module, or the power switches may also be located on the upper surface of the transformer module, which is not limited in this application.

The power switch may be a diode, a Metal-Oxide-Semiconductor Field-Effect Transistor (MOSFET), an Insulated Gate Bipolar Transistor (IGBT), or the like.

Specifically, one or more chips (barrel die) of the power switch SR connected in parallel may be directly integrated in a carrier by an Embedded (Embedded) process to form the switch module, but the application is not limited thereto. The power switch may be disposed just below the pins of the switch module to facilitate connection with the pins. Referring to fig. 3D, in this embodiment, although the number of the first pin V0 and the second pin D2 is one, if the size of the power switch or the size of the external connection pin of the switch module is smaller than that of the transformer module, a plurality of SRs connected in parallel may be connected to the pins as shown in the figure, and the SRs may be uniformly distributed on the pins or may not be uniformly distributed on the pins; the embodiment shown in fig. 5 may also be similarly arranged. Referring to fig. 4B, in this embodiment, the teeth of the fifth pins D1 and the second pins D2 can be used to connect to the power switches. Fig. 6E is a bottom view of the switch module according to an embodiment of the disclosure, and as shown in fig. 6E, the lower surface of the carrier board may form an output PIN (PIN), such as VOUT, GND, etc., of the transformer power unit. And then, welding the corresponding transformer module to the carrier plate to form the power module, as shown in fig. 6C and 6D.

Or firstly welding one or more parallel-connected SRs on the surface of the carrier plate, then forming the switch module through an injection molding (molding) process, forming a bonding pad corresponding to the transformer module on the other surface of the carrier plate, and welding the transformer module on the surface of the carrier plate to form the power module.

Further, the power module further includes a capacitor module, the capacitor module is located on the carrier and disposed adjacent to the transformer module, as shown in fig. 6F and other diagrams, the capacitor module may be electrically connected to the second pin D2, or as shown in fig. 7 and other diagrams, the capacitor module may also be electrically connected to the first pin V0, which is not limited in the disclosure. The power module may further include an LLC power unit, a controller, etc. to make the power module function as an LLC converter, and specifically, fig. 6F is a cross-sectional view of a power module provided in an embodiment of the present application, as shown in fig. 6F, where Co is an output capacitor.

It should be noted that the power module is not limited to the LLC converter, and the power module is also applicable to any circuit including a transformer module, such as a flyback converter, a full-bridge circuit, and the like.

Example four

On the basis of the third embodiment, the present application further provides a power module, wherein the power module includes a transformer module as in the second embodiment, and a second insulating layer and a third wiring layer are further sequentially disposed on the magnetic core, and the second insulating layer is at least partially covered by the second metal winding. The transformer module further includes: the third metal winding is formed on the third wiring layer and wound on the magnetic core in a foil mode, wherein the third metal winding is at least partially covered by the second insulating layer; and a fifth pin, the fifth pin being located on a first surface (e.g., a bottom surface) of the transformer module, a first end of the third metal winding being electrically connected to the fifth pin D1 through a third connector (e.g., a via), a second end of the third metal winding being electrically connected to the first pin V0, and the rest of the components are not described again.

Fig. 7 is an electrical schematic diagram of each terminal of a power module according to an embodiment of the present disclosure, and as shown in fig. 7, after the transformer module and the switch module are stacked, the switch module is further electrically connected to a fifth pin D1.

Further, as shown in fig. 7, the power module further includes a first power Switch (SR) and a second power Switch (SR), wherein a first terminal of the first power switch is electrically connected to the second pin D2, a first terminal of the second power switch is electrically connected to the fifth pin D1, and a second terminal of the first SR is electrically connected to a second terminal of the second SR, but the invention is not limited thereto, and each illustrated power switch may actually be equivalent to a plurality of power switches connected in parallel according to the power class of the device.

Furthermore, the power module further includes a capacitor module, for example, serving as an LC resonant capacitor or an output capacitor, and the invention is not limited thereto. As shown in fig. 6F, where Co may be the output capacitance. The capacitor module may be electrically connected to the first pin V0. The capacitor can be placed in a plurality of positions, for example, the capacitor module can be located on the carrier board and disposed adjacent to the transformer module, for example, as shown in fig. 6F; or the carrier plate and the switch device SR can be adjacently arranged on the same side of the carrier plate; can also be embedded into the carrier plate; or in a window of the transformer, for example, when the magnetic core of the transformer in fig. 6F is a square magnetic core, the capacitor can be placed in the window of the magnetic core, and so on; even though the capacitor is placed on the top surface of the core, the device SR is placed on the bottom surface of the core. The power module may further include an LLC primary power unit, a controller, etc., such that the power module functions as an LLC converter.

It can be seen that the power module is easy to be produced in a modularized manner, and the plurality of SRs are integrated on one carrier plate to form the switch module, and then the plurality of transformer modules are attached to the switch module, and finally cut, so that a plurality of power modules can be produced at one time, but the invention is not limited thereto.

Furthermore, the power switch is directly connected with the output PINs of the transformer module, so that the connection loss is low; the primary and secondary loops of the transformer module are directly coupled together, and the winding alternating current impedance and the alternating current loss are small, but the invention is not limited to this.

In the first to fourth embodiments, the correspondence between the pins is (but not limited to):

the first pin corresponds to V0, and as can be seen from fig. 3E, 4C, 6A, 6B, and 7, it may correspond to the first end of the first metal winding S2, the second end of the third metal winding S1, and so on, and may serve as an output terminal of the module;

the second pin corresponds to D2, and as can be seen from fig. 3E, 4C, 6A, 6B, and 7, the second pin may correspond to the second end of the first metal winding S2, and may be used for connecting to a power switch, a secondary side ground, and the like;

the third pin corresponds to P1, the fourth pin corresponds to P2, and the third pin and the fourth pin can respectively correspond to two ends of the second metal winding P;

the fifth pin corresponds to D1, and as can be seen from fig. 3E, 4C, 6A, 6B, 7, etc., may correspond to the first end of the third metal winding (as the secondary winding S1), and may be used for connection with a power switch, a secondary ground, etc.;

however, in some other embodiments in the present application, as in the fifth to ninth embodiments, for convenience of description, the electrical connection point corresponding to each pin is different from the electrical connection point corresponding to the foregoing embodiment, and the present application is not limited thereto.

EXAMPLE five

In the above embodiments, the windings of the transformer may be located in the same wiring layer, but the invention is not limited thereto. Fig. 8 shows a cross-sectional view AA' of the transformer module of fig. 5, from which it can be seen that the windings are located in a first, a second and a third wiring layer, respectively, wherein the first, the second and the third wiring layer are arranged in sequence from the outside inwards. In fig. 8, the via connecting the first lead-out of the third wiring layer to the second pin D1 is shown by a dotted line because the via and the other lead-out via of the winding are not in the same cross section.

In practice, the windings may also be placed in staggered layers, that is, the same winding may be located in different layers of wiring layers, for example, two layers of wiring layers, for example, a first wiring layer, a first insulating layer, and a second wiring layer are sequentially disposed on the magnetic core from inside to outside. Fig. 9A and 9B show cross-sectional views of such winding arrangements. As shown in fig. 9A and 9B, 191 is a magnetic core; the first metal winding is wound on the magnetic core 191 and comprises a first section of winding 1922 formed on the first wiring layer and a second section of winding 1921 formed on the second wiring layer, a first end of the first section of winding 1922 is electrically connected to a first end of the second section of winding 1921 through a via, a second end of the first section of winding 1922 is electrically connected to the first pin V0 through a via, and a second end of the second section of winding 1921 forms a second pin D1; the second metal winding, also foil-wound around the magnetic core 191, includes a third winding 1941 disposed on the first wiring layer and a fourth winding 1942 formed on the second wiring layer, and a second end of the third winding 1941 is connected to the pin V0 through a via. As shown in the figure, a first end of the third segment of winding 1941 is connected to a first end of the fourth segment of winding 1942 by a via, and a second end of the fourth segment of winding 1942 forms a third pin D2. Thus, the first and second metal windings form a connection structure of the secondary windings S1 and S2 of the transformer as shown in fig. 7. The winding P of the transformer in fig. 7 is a foil-wound third metal winding 193 in fig. 9A-9B at a third wiring layer, which may be sequentially located between the first and second insulating layers. Compared with the arrangement mode that the same winding is positioned on the same wiring layer shown in fig. 8, the arrangement mode that the secondary windings S1 and S2 in fig. 7 are arranged by a staggered arrangement method greatly improves the symmetry between the two windings, so that the current equalizing effect of the circuit flowing through the first and second SRs is improved remarkably in the working process. In addition to the staggered arrangement of the windings in fig. 7, which may also be used in the windings of fig. 6A-6F, the second end of the third segment of the second metal winding is connected to a pin other than V0 on the transformer surface by a via. Thus, 4 pins will be formed on the transformer surface, and the first and second metal windings also become two independent windings, such as winding P and winding S2 in fig. 6B.

The design of the leads may be similar to that of the other embodiments of the present application, for example, the third leads D2 are plural, the second lead D1 includes plural teeth, and the plural teeth are staggered with the plural third leads D2; alternatively, the second pins D1 and the third pins D2 are plural, and the plural second pins D1 and the plural third pins D2 are arranged in a staggered manner; as shown in fig. 9C, fig. 9C is a bottom view of the transformer according to an embodiment of the present invention, which includes a first pin V0, a second pin D1, and a third pin D2, wherein the first pin V0 is located between the second pin D1 and the third pin D2, and the length of each pin is almost equal to the average length of the windings; the first, second and third leads may be square or distributed on a part of the winding as shown in fig. 9D, and the plurality of leads are symmetrically arranged, which is not limited in this application.

The corresponding power module may include a switch module. Similar to fig. 7, the switch module includes a plurality of first SRs and a plurality of second SRs; a first end of the first SR is connected to the first pin D1, a first end of the second SR is connected to the third pin D2, and a second end of the first SR is electrically connected to a second end of the second SR; according to the difference of the transformer pins, the plurality of first SRs (i.e. SR1 in fig. 9E) and the plurality of second SRs (i.e. SR2 in fig. 9E) can be separated into two rows, as shown in fig. 9E. Fig. 9E is a schematic diagram of a portion of the transformer and the switching elements disposed thereon, which is cut off by a dashed frame in fig. 9C. The partial transformer module comprises three pins D1, D2 and V0, wherein the pin V0 is arranged between the pins D1 and D2, a switch module is arranged on the transformer module and comprises a plurality of SR1 and a plurality of SR2, the plurality of SR1 and the plurality of SR2 are separated into two rows, and the switch module is in contact with one side of the transformer. In addition, the power switches may be arranged in the same row, wherein SR1 and SR2 are arranged in a staggered manner, which is not limited in this application. Of course, the switch module may further include a carrier board, and the switch may be placed on the carrier board or embedded in the carrier board.

Further, the power module may further include a capacitor module, where the capacitor module includes a plurality of capacitor units, and the capacitor module may be located on the carrier and disposed adjacent to the transformer module, as shown in fig. 6F; in addition, it may also be located below the carrier, as shown in fig. 9F, the capacitor Co is located below the power switch, and the capacitor module is located at the lower end of the SR. Of course, Co may also be embedded in the carrier plate, or placed on the other side of the transformer opposite the switch module, e.g. the upper side of the transformer module in fig. 9F; co may also be placed in the window of the core. In summary, the location of the capacitive module is varied.

EXAMPLE six

In the embodiments described above, the transformer winding is formed by electroplating, and the pins are led out by means of the vias, but the invention is not limited thereto. As shown in fig. 8, the winding of the transformer is a winding layer formed by electroplating or electroless plating, and the pins D1 and V0 are connected with the inner winding by means of vias, but the invention is not limited thereto.

In practice, the transformer winding may also be formed by winding a metal foil, such as a copper foil. Fig. 10A is a cross-sectional view of a transformer according to an embodiment of the present invention, as described in the second embodiment, the transformer module includes, from outside to inside, a first metal winding 1104, a second metal winding 1103, and a third metal winding 1102, an initial insulating layer is filled between the third metal winding and the magnetic core, a second insulating layer is filled between the third metal winding and the second metal winding, and a first insulating layer is filled between the second metal winding and the first metal winding. The second metal winding 1103 may be used as the primary winding P, the third metal winding 1102 may be used as the secondary winding S1, and the first metal winding 1104 may be used as the secondary winding S2, thereby forming a "sandwich" structure in which two secondary windings sandwich the primary winding. The third metal winding 1102 is a unitary copper layer that surrounds the core leg 1101 such that the core leg 1101 is at least partially covered by the initial insulation layer and the third metal winding 1102, the same third metal winding 1102 is also at least partially covered by the second insulation layer and the second metal winding 1103, and the second metal winding 1103 is at least partially covered by the first insulation layer and the first metal winding 1104.

Similar to the second embodiment, the third metal winding 1102 includes two ends, which are divided into a first end and a second end, wherein the first end is connected to the fifth pin of the outermost layer, such as pin D1, for making an electrical connection with the outside. A second end of third metal winding 1102 is commonly connected to an end of first metal winding 1104 and is commonly connected to an outermost first pin, such as pin V0. Unlike the second embodiment, the pins led out from the first end of the third metal winding 1102 and the second end of the third metal winding 1102 are not led out through vias. Fig. 10B-10F illustrate one way in which a metal foil, such as copper foil, is integrally formed.

First, a whole metal foil, for example, a copper foil is cut into a structure shown in fig. 10B (i.e., an expanded view of the third metal winding). Cutting a structure in a shape of a 'notch' as shown in the figure on two parallel edges of the copper foil respectively, wherein the structure is used for forming

pins

1001 and 1002 of the layer of winding; then, the copper foil is folded according to the chain line shown in the figure. The folded shape is shown in fig. 10C. Then, winding a strip-shaped copper foil serving as a second metal winding of the transformer on the surface of a third metal winding, wherein

pins

1001 and 1002 of the third metal winding which are erected are avoided in the winding process, as shown in fig. 10D; and finally, manufacturing the first metal winding by adopting a process similar to the process for manufacturing the third metal winding. Cutting and folding a whole piece of copper foil into a first metal winding as shown in fig. 10E, cutting a hole 1003 corresponding to the

1001 or 1002 of the third metal winding at one end of the first metal winding to allow the pin of the third metal winding to protrude from the hole (in the figure, two holes 1003 allow the

1001 or 1002 to pass through respectively, and actually two holes can be punched to form one hole); and finally, insulating the first end pin of the third metal winding, bending the first end pin, then flatly laying the bent first end pin on the surface of the first metal winding to form a fifth pin D1, bending the second end pin of the third metal winding, flatly laying the bent second end pin on the surface of the first metal winding, and connecting to form a first pin V0, as shown in FIGS. 10F-G.

Alternatively, there may be a plurality of first, fifth and second leads, and a plurality of first leads V0 are located between the fifth lead D1 and the second lead D2, and the first, second and fifth leads are arranged in a row, as shown in fig. 10G, which is not limited thereto.

In this embodiment, the inner winding, the connecting member, and the pins are integrally formed, and the pins penetrate through the insulating layer between the windings and the wiring layer where the outer winding is located. For example, the pin of the third metal winding passes through the insulating layer between the third winding and the second winding, the insulating layer between the second winding and the first winding, and then is bent on the surface of the first winding.

Taking the insulation of the third metal winding 1102 as an example, the insulation requirement of the third metal winding includes an initial insulation layer on the inside thereof and a second insulation layer on the outside thereof. The initial insulation layer is used for insulation from the core leg 1101 and the second insulation layer is used for insulation from the second metal winding 1103. The thickness of the insulating layer is required to be determined by the interlayer withstand voltage and the interlayer distributed capacitance, for example, in this example, the thickness of the insulating layer is required to be 70 um. Additional requirements for the insulating layer include a certain degree of wraparound.

In response to these needs, the present application proposes a new method for manufacturing an insulating layer, how to effectively process the insulating layer between different metal wiring layers and between the wiring layers and the magnetic core pillar. The method and process for making the insulating layer will be described in detail by taking the insulation of any metal winding as an example. In the first step, the cut and formed metal foil, such as the metal of the third wiring layer shown in fig. 10B, is subjected to surface roughening treatment, including mechanical polishing or chemical roughening and browning, wherein the chemical browning is the most preferable. The purpose of the surface roughening is to increase the contact surface area of the metal layer and the insulating material, so that the adhesive force of the insulating material is increased, and the metal layer and the insulating material are prevented from being layered and peeled off during subsequent bending. Secondly, a first insulating layer forming is performed on the roughened metal layer 1102 to form an inner base insulating layer, as shown in fig. 10B-1, 1102 is the metal layer, and 1006 is the insulating layer. The insulation method comprises the methods of electric coating, spraying or printing and the like. Among them, the electro-deposition method is preferred, the requirement on the shape of the metal layer is the lowest, the insulation on the part difficult to process such as the corner of the metal layer is more reliable, and the adhesion performance is better. For example, the electro-deposition material may be acrylic electro-deposition paint, which is composed of polyacrylic resin and polyurethane (commonly called PU) hardening agent. The portion 1007 where the connection terminal is required can be kept away by covering and shielding in advance. And a third step of performing a second insulating layer formation after the first insulating layer formation to form an auxiliary insulating layer on the outer side, as shown in fig. 10B-2. The thickness of the insulating layer that can be made by the electrical method is limited, and typically, the thickness is between 0.1 um and 30 um. Therefore, when the requirement of the thickness of the insulating layer is greater than 30um, as shown in the requirement of the present embodiment, the insulating layer needs to be formed again. The second insulating layer may be formed, for example, by providing an insulating paste, such as printed insulating paste 1008 as shown in fig. 10B-2. Certainly, the auxiliary insulation layer process is not limited to printing insulation paste, and can also be performed by processes such as photoresist lamination, local dispensing, and the like. As an example, the material of the auxiliary insulating layer may be selected from photosensitive photoresist such as epoxy resin based material. In order to avoid cracking of the insulating layer when the metal layer is bent, only partial printing may be performed, as shown in fig. 10B-2 and 10B-3. FIG. 10B-2 is a schematic cross-sectional view of the metal layer before bending, and FIG. 10B-3 is a schematic cross-sectional view of the metal layer after bending. It can be seen in the figure that there is no printed insulating material at the corner portions where bending is desired. The second dielectric shaping increases the total dielectric thickness. Of course, this step is not necessary, and in the case of a low thickness requirement, one time of insulating layer formation may suffice. Finally, an adhesive layer may be optionally coated after the insulating layer is completed to achieve adhesion and fixation between the plurality of metal wiring layers.

Summarizing the manufacturing process of a metal winding is shown in fig. 10B-4. Step S1, cutting the first metal foil to form connectors and pins; step S1.1: roughening the surface of at least one of the first metal foil and the second metal foil; step S2.1: performing first insulation treatment on the surface of at least one metal foil of the first metal foil and the second metal foil to form an inner base insulation layer; step S2.2: performing a second insulation treatment on the surface of the metal foil forming the base insulation layer to form an outer auxiliary insulation layer; step S2.3: coating a surface adhesion layer of at least one of the first metal foil and the second metal foil; step S3: and bending the first metal foil to form a first metal winding which is coated on the magnetic core. Step S4: and at least partially coating a second metal foil on the surface of the first metal winding to form a second metal winding, wherein the pin of the first metal winding passes through the second metal winding. Step S5: and cutting the third metal foil to form a through hole or a gap, bending the third metal foil and coating the third metal foil on the surface of the second metal winding to form a third metal winding, wherein the pin of the first metal winding penetrates through the through hole or the gap.

Wherein, step S1.1, step S2.2, step S2.3 are optional steps. It should be noted that, the present application does not limit the sequence before the above steps, for example: step S2.1 and step S2.2 may be performed before step S1 or after step S1. In some embodiments, the second metal foil in step S4 is an elongated copper foil, which is used as a second metal winding and is wound on the surface of the first metal winding, and a via hole or a void is formed during the winding process to allow the pin of the first metal winding to pass through.

The power module in the fifth embodiment can be referred to as a corresponding power module, and details are not repeated here.

In the circuit schematic shown in fig. 7, for example, if the secondary windings S1 and/or S2 are segmented to lead out connection terminals on different sides of the transformer module, the positions of the first SR and/or the second SR are not necessarily limited to be connected to the bottom side of the transformer module, but are electrically connected in series through pins S1 ', D1, and/or S2', D2 in fig. 12A and 12B, for example, and devices can be flexibly arranged on multiple surfaces, which is beneficial to optimizing the spatial distribution. This section will be further described in example seven through example nine.

EXAMPLE seven

Fig. 11A and 11B are respectively a schematic structural diagram of a transformer module according to an embodiment of the present disclosure, fig. 12A is a cross-sectional view of a transformer module according to an embodiment of the present disclosure taken along line AB shown in fig. 11A, fig. 12B is a cross-sectional view of a transformer module according to an embodiment of the present disclosure taken along line AB shown in fig. 11B, and dotted lines in fig. 12A and 12B indicate omitted portions. Specifically, as shown in fig. 11A and 12A, the transformer module includes:

and the magnetic core 91 is provided with a first wiring layer, a first insulating layer, a second wiring layer, a second insulating layer and a third wiring layer from inside to outside in sequence.

The first metal winding, foil-wound on the magnetic core 91, includes a first segment winding 922 formed on the first wiring layer and a second segment winding 921 formed on the second wiring layer, and a first end of the first segment winding 922 is electrically connected to the first pin D1 through a via. The second end of the first segment of winding 922 is electrically connected to the second pin V0 through a via hole, the first end of the second segment of winding 921 forms a third pin S1 ', the first pin D1 and the third pin S1' are both located on the first surface of the transformer module, the second end of the second segment of winding 921 forms a fourth pin GND, and the second pin V0 and the fourth pin GND are both located on the second surface of the transformer module. After the corresponding electronic device, such as a switching element, is electrically connected to the first pin D1 and the third pin S1', the first winding segment 922 formed on the first wiring layer and the second winding segment 921 formed on the second wiring layer are electrically connected in series. And a third metal winding 93 formed in the third wiring layer and foil-wound around the magnetic core 91. In one embodiment, the third metal winding 93 can be used as the primary winding P, and the first metal winding can be used as the secondary winding S1, for example, corresponding to fig. 3E.

Optionally, as shown in fig. 11B and 12B, the transformer module further includes:

the second metal winding, foil-wound on the magnetic core 91, includes a third winding 941 formed on the first wiring layer and a fourth winding 942 formed on the second wiring layer, a first end of the third winding 941 is connected to the fifth pin D2 through a via 95, a second end of the third winding 941 is electrically connected to the second pin V0, a first end of the fourth winding 942 forms a sixth pin S2 ', a second end of the fourth winding 942 is electrically connected to the fourth pin GND, and the fifth pin D2 and the sixth pin S2' are both located on the first surface of the transformer module. In one embodiment, the third metal winding 93 can be used as the primary winding P, the first metal winding can be used as the secondary winding S1, and the second metal winding can be used as the secondary winding S2, for example, corresponding to fig. 4C.

Alternatively, after the corresponding electronic device, such as a switching element, is electrically connected to the fifth pin D2 and the sixth pin S2', the third winding 941 formed on the first wiring layer and the fourth winding 942 formed on the second wiring layer are electrically connected in series.

Alternatively, the transformer module may include the first metal winding and the second metal winding, and the third metal winding and the corresponding wiring layer and insulating layer are omitted, and the first metal winding and the second metal winding are respectively used as the primary winding P and the secondary winding S1 of the transformer module, for example, corresponding to fig. 3E. The present application is not limited thereto.

Alternatively, the via holes may be located at about 1/2 lengths of the first metal winding 92 and the second metal winding, for example, when the number of turns of the first metal winding and the second metal winding is one turn, the first winding section 922, the second winding section 921, the third winding section 941 and the fourth winding section 942 are wound around the magnetic core 91 by half turns, but the application is not limited thereto, and the number of turns of the first metal winding and the third metal winding is not limited to one turn.

Optionally, the first and second faces of the transformer module are opposing faces. For example: the first side of the transformer module may be an upper surface of the transformer module, and the second side of the transformer module may be a lower surface of the transformer module. Alternatively, the first side of the transformer module may be one side of the transformer module and the second side of the transformer module may be the other side of the transformer module. The specific locations of the first and second faces are not limited in this application.

Optionally, the magnetic core is square, annular, I-shaped or C-shaped.

The distribution of the first pin D1, the fifth pin D2, the third pin S1 'and the sixth pin S2' of the transformer module is explained as follows:

alternatively, fig. 13A is a top view of the transformer module according to an embodiment of the disclosure, as shown in fig. 13A, the first pins D1 are plural, the fifth pins D2 are plural, the plural first pins D1 and the fifth pins D2 are arranged in a staggered manner, and the plural first pins D1 and the plural fifth pins D2 are located between the third pin S1 'and the sixth pin S2'.

Alternatively, fig. 13B is a top view of a transformer module according to another embodiment of the present disclosure, as shown in fig. 13B, the first lead D1 is square, the fifth lead D2 is square, and the first lead D1 and the fifth lead D2 are both located between the square third lead S1 'and the square sixth lead S2'. When the lead-out pins at both ends of the second metal winding are disposed on the first surface, the pins located on the first surface, such as the first pin D1 and the fifth pin D2, may have other shapes, such as a C-shape, and the application is not limited thereto.

Fig. 14A is a bottom view of a transformer module according to an embodiment of the present application, and as shown in fig. 14A, an output PIN may be formed on a lower surface of the transformer module, for example: VOUT, GND, etc. Fig. 14B is a bottom view of a transformer module according to another embodiment of the present disclosure, and as shown in fig. 14B, an output PIN may be formed on a lower surface of the transformer module, for example: VOUT, GND, etc.

An embodiment of the present application further provides a transformer module, in which a transformer winding of a foil winding structure directly wraps a transformer magnetic pole, so that equivalent diameters of the respective portions of the foil winding structure winding are close to each other, and equivalent impedances are close to each other, thereby achieving an effect of uniform distribution of winding current.

Example eight

Fig. 15 is a cross-sectional view of a power module according to another embodiment of the present application, as shown in fig. 15, the power module includes:

a transformer module 121 as in embodiment seven.

A switch module 122, the switch module 122 contacts a first surface (e.g., an upper surface having pins) of the transformer module 121 and is electrically connected to the first pin D1, the third pin S1 ', the fifth pin D2, and the sixth pin S2'.

Optionally, the switch module 122 includes a carrier 124 and at least two power Switches (SR)123, as shown in fig. 15, the switch module 122 includes the power Switches (SR)123, and the power switches 123 are disposed on the carrier 124. At least one first SR is electrically connected to the first pin D1 and the third pin S1 ', and at least one second SR is electrically connected to the fifth pin D2 and the sixth pin S2'. The power switches may be located on the lower surface of the transformer module, or the power switches may also be located on the upper surface of the transformer module, which is not limited in this application.

Example nine

Fig. 16 is a top view of a power module according to another embodiment of the present application, as shown in fig. 16, the power module includes:

a transformer module as in embodiment seven;

the at least one first SR contacts a first surface (e.g., an upper surface having pins) of the transformer module and is electrically connected to the first pin D1 and the third pin S1';

the at least one second SR contacts the first surface (e.g., the upper surface having the leads) of the transformer module and is electrically connected to the fifth lead D2 and the sixth lead S2'.

Wherein, the SR can be a diode, a MOSFET or an IGBT. The first SR and the second SR may be respectively packaged as a switch module, or may be integrated as a switch module, which is not limited in this application.

Specifically, one or more unpackaged chips (bare die) connected in parallel with the SR are directly integrated into a carrier by an Embedded (Embedded) process to form the switch module. And forming a bonding pad corresponding to the transformer module on the lower surface of the carrier plate, and welding the switch module and the transformer module together to form the power module.

Further, the power module further includes: and the capacitor module is in contact with the second surface of the transformer module and is electrically connected with the second pin and the fourth pin. Specifically, the power module may further include an LLC primary power unit, a controller, and the like, such that the power module functions as an LLC converter. Alternatively, as shown in fig. 16, the capacitance module includes: and Co, wherein Co is the output capacitance.

Alternatively, the power module may only include the primary power unit, the resonant unit, the controller, the output capacitor, and the like.

In embodiments seven to nine, the first metal winding, the second metal winding S1 and/or S2 in the circuit schematic shown in fig. 7, for example, may be respectively formed in segments to lead out connection terminals on different sides of the transformer module.

In some embodiments, such as the seventh embodiment to the ninth embodiment, the correspondence between the pins is (but not limited to):

as can be seen from fig. 7 and 12A, the first pin corresponds to D1, the third pin corresponds to S1, and both ends of the switch (e.g., a diode) can be electrically connected to the first pin and the third pin, respectively, so as to form a serial connection relationship between the switch and the first metal winding, corresponding to a discontinuity formed by segmenting the first metal winding;

the second pin corresponds to V0, and as can be seen from fig. 7 and the like, can be used as an output terminal of the module;

the fourth pin corresponds to GND and can be used for being connected with secondary side grounding and the like;

as can be seen from fig. 7 and 12B, the fifth pin corresponds to D2, the sixth pin corresponds to S2, and both ends of the switch (e.g., a diode) can be electrically connected to the fifth pin and the sixth pin, respectively, corresponding to the break point formed by segmenting the second metal winding, so as to form a serial connection relationship between the switch and the first metal winding.

However, in the seventh to ninth embodiments of the present application, for convenience of description, the electrical connection point corresponding to each pin is different from the electrical connection point corresponding to the first to fourth embodiments, and the application is not limited thereto.

In the transformer module according to the foregoing embodiments, pins may be led out from two ends of the third metal winding, and may be led out to the first surface, the second surface, or other surfaces, which is not limited in this application; the shape of each pin is not limited to the square, C, or other shapes shown in the figures, and can be flexibly changed according to practical application.

The pins in the foregoing embodiments are surface mount pins, and actually, the pins may be in other forms, such as in-line pins.

The metal windings of the transformer module in the foregoing embodiments may flexibly correspond to primary windings and secondary windings of different types of transformers, for example, may be used in a common transformer as shown in fig. 3E, may also be used in a secondary tap transformer (connected in series with two secondary windings), may also be used in a transformer with multiple independent secondary windings, and the like, and the application is not limited thereto.

Claims

1. A transformer module, comprising:

the first metal winding is wound on the magnetic core in a foil mode and comprises a first section of winding formed on the first wiring layer and a second section of winding formed on the second wiring layer, the first end of the first section of winding is electrically connected to a first pin through a first connecting piece, the second end of the first section of winding is electrically connected to a second pin through a second connecting piece, the first connecting piece and the second connecting piece penetrate through the first insulating layer, the first end of the second section of winding forms a third pin, the first pin and the third pin are located on the first surface of the transformer module, the second end of the second section of winding forms a fourth pin, and the second pin and the fourth pin are located on the second surface of the transformer module;

the second metal winding is wound on the magnetic core in a foil mode and comprises a third section of winding formed on the first wiring layer and a fourth section of winding formed on the second wiring layer, the first end of the third section of winding is connected to a fifth pin through a third connecting piece, the second end of the third section of winding is connected to the second pin through a fourth connecting piece, the third connecting piece and the fourth connecting piece penetrate through the first insulating layer, a sixth pin is formed at the first end of the fourth section of winding, the second end of the fourth section of winding is electrically connected to the fourth pin, and the fifth pin and the sixth pin are located on the same face of the transformer module.

2. The transformer module of claim 1, wherein at least one of the first, second, third, and fourth connectors is a via or the metal winding to which the connector is connected is a unitary piece, and is formed by cutting and folding the metal winding.

3. The transformer module of claim 1, wherein a third wiring layer and a second insulating layer are further disposed on the core, wherein the third wiring layer and the second insulating layer are sequentially disposed between the first insulating layer and the second wiring layer; and

and a third metal winding, which is wound on the magnetic core and is positioned on the third wiring layer.

4. The transformer module of claim 3, wherein the first metal winding has one turn, the third metal winding has a plurality of turns to form a spiral winding around the core, and the second metal winding has one turn.

5. The transformer module of claim 1, wherein the first pins are plural, the fifth pins are plural, and the plural first pins and fifth pins are arranged in a staggered manner, and the plural first pins and the plural fifth pins are located between the third pins and the sixth pins.

6. The transformer module of claim 1, wherein the first lead is C-shaped or square-shaped, the fifth lead is C-shaped or square-shaped, and the first lead and the fifth lead are both located between the third lead of the C-shaped or square-shaped and the sixth lead of the C-shaped or square-shaped on the first face.

7. The transformer module of claim 1, wherein the second leg is surrounded by the fourth leg on the second side.

8. The transformer module of claim 1, wherein the first and second faces of the transformer module are opposing faces.

9. The transformer module of claim 1,

1/2 where the length of the first pin is greater than or equal to the length of the first metal winding; and/or the presence of a gas in the gas,

1/2 where the length of the second leg is greater than or equal to the length of the first metal winding; and/or the presence of a gas in the gas,

1/2 where the length of the third leg is greater than or equal to the length of the first metal winding; and/or the presence of a gas in the gas,

the length of the fourth pin is greater than or equal to 1/2 of the length of the first metal winding; and/or the presence of a gas in the gas,

1/2 where the length of the fifth pin is greater than or equal to the length of the second metal winding; and/or the length of the sixth pin is greater than or equal to 1/2 the length of the second metal winding.

10. The transformer module of claim 1,

the first pins are plural, and the total length of the plural first pins is greater than or equal to 1/2 of the length of the first metal winding; and/or the presence of a gas in the gas,

the third pins are plural, and the total length of the plurality of third pins is greater than or equal to 1/2 of the length of the first metal winding; and/or the presence of a gas in the gas,

the fourth pins are plural, and the total length of the plural fourth pins is greater than or equal to 1/2 of the length of the first metal winding; and/or the presence of a gas in the gas,

the fifth pins are plural, and the total length of the plurality of fifth pins is greater than or equal to 1/2 of the length of the second metal winding; and/or the presence of a gas in the gas,

the sixth pins are plural, and the total length of the sixth pins is greater than or equal to 1/2 of the length of the second metal winding.

11. The transformer module of claim 1, wherein the first insulating layer comprises a base insulating layer and an auxiliary insulating layer.

12. The transformer module of claim 1, wherein the base insulating layer is insulated by an electro-deposition process; the auxiliary insulating layer is made of insulating glue which is locally arranged.

13. A power module, comprising:

a transformer module according to claim 1;

a switch module in contact with the first face of the transformer module.

14. The power module of claim 1, further comprising:

15. The power module of claim 1, wherein the switch module is electrically connected to the first pin, the third pin, the fifth pin, and the sixth pin.

16. The power module of claim 1, wherein the switch module comprises a plurality of first power switches and a plurality of second power switches, the plurality of first power switches and the plurality of second power switches are disposed on a first side of the transformer module, the plurality of first power switches are electrically connected to the first pin and the third pin, and the plurality of second power switches are electrically connected to the fifth pin and the sixth pin.

17. A transformer module, comprising:

the first metal winding is wound on the magnetic core in a foil mode and comprises a first section of winding formed on the first wiring layer and a second section of winding formed on the second wiring layer, the first end of the first section of winding is electrically connected to the first end of the second section of winding through a first connecting piece, the second end of the first section of winding is electrically connected to the first pin through a second connecting piece, the second end of the second section of winding forms a second pin, and the first connecting piece and the second connecting piece penetrate through the first insulating layer;

the second metal winding is wound on the magnetic core in a foil mode and comprises a third section of winding formed on the first wiring layer and a fourth section of winding formed on the second wiring layer, the first end of the third section of winding is connected to the first end of the fourth section of winding through a third connecting piece, the second end of the fourth section of winding forms a third pin, and the third connecting piece penetrates through the first insulating layer.

18. The transformer module of claim 17, wherein at least one of the first, second, third, and fourth connectors is a via or the metal winding to which the connector is connected is a unitary piece, and is formed by cutting and folding the metal winding.

19. The transformer module of claim 17, wherein the second end of the third segment of winding is electrically connected to the first pin.

20. The transformer module of claim 19, wherein the first pin, the second pin, and the third pin are located on a first side of the transformer module.

21. The transformer module of claim 19, wherein a second insulating layer and a third wiring layer are further disposed on the core, wherein the third wiring layer and the second insulating layer are sequentially disposed between the first insulating layer and the second wiring layer; and

22. The transformer module of claim 21, wherein the third leads are plural, the second leads further comprise plural teeth, and the plural teeth are staggered from the plural third leads.

23. The transformer module of claim 21, wherein the second and third leads are both plural, and the plural second leads and the plural third leads are staggered.

24. The transformer module of claim 19, wherein the core comprises a through hole, and wherein the first leg, the second leg, and the third leg are C-shaped or t-shaped around the through hole, and the first leg is intermediate the second leg and the third leg.

25. The transformer module of claim 19, wherein the core comprises a through hole, and wherein the first, second, and third leads are each a plurality, and wherein the first leads, the second leads, and the third leads are each arranged around the through hole, and wherein the first leads are intermediate the second leads and the third leads.

26. The transformer module of claim 19,

the length of the third pin is greater than or equal to 1/2 the length of the first metal winding.

27. The transformer module of claim 19,

the third pins are plural, and the total length of the plural third pins is greater than or equal to 1/2 of the length of the first metal winding.

28. The transformer module of claim 19, wherein the first insulating layer comprises a base insulating layer and an auxiliary insulating layer.

29. The transformer module of claim 28, wherein the base insulating layer is insulated by an electro-deposition process; the auxiliary insulating layer is made of insulating glue which is locally arranged.

30. A power module, comprising:

a transformer module according to claim 19, wherein said first leg, said second leg, and said third leg are each located on a first side of said transformer module;

a switch module in contact with the first face of the transformer module.

31. The power module of claim 30, wherein the switch module comprises a carrier and at least one power switch, the power switch is disposed on the carrier, and the power switch is electrically connected to the first pin and/or the second pin.

32. The power module of claim 30, further comprising:

the capacitor module is positioned on the carrier plate and is arranged close to the transformer module, and the capacitor module is electrically connected with the first pin or the second pin; or,

the capacitor module is positioned on the same side of the carrier plate and adjacent to the switch module; or,

the capacitor module is embedded in the carrier plate; or,

the capacitor module is positioned in a window of the transformer module; or,

the capacitor module is positioned on the upper surface of the transformer module; or

The capacitance module is located below the power switch.

33. The power module of claim 31, wherein the switch module comprises a plurality of first power switches connected in parallel and a plurality of second power switches connected in parallel, the plurality of first power switches and the plurality of second power switches being arranged in two separate rows.

34. A method of manufacturing a metal winding in a transformer module, comprising:

cutting the first metal foil to form a connecting piece and a pin;

performing insulation treatment on the surface of at least one of the first metal foil and the second metal foil;

bending the first metal foil to form a first metal winding, and coating the first metal winding on the magnetic core;

and at least partially coating the second metal foil on the surface of the first metal winding to form a second metal winding, wherein the pin of the first metal winding passes through the second metal winding.

35. The manufacturing method according to claim 34, wherein the insulating treatment of the surface of at least one of the first metal foil and the second metal foil includes:

carrying out first insulation treatment on the surface of the at least one metal foil to form an inner base insulation layer;

and performing second insulation treatment on the metal foil forming the base insulation layer to form an auxiliary insulation layer on the outer side.

36. The method of claim 35, wherein the base insulating layer is insulated by an electro-deposition process.

37. The manufacturing method according to claim 35, wherein the auxiliary insulating layer is a partially disposed insulating paste.

38. The manufacturing method according to claim 34, further comprising, before performing the insulating treatment on the surface of at least one of the first metal foil and the second metal foil:

and roughening the surface of the at least one metal foil.

39. The manufacturing method according to claim 35, further comprising, after performing an insulating process on a surface of at least one of the first metal foil and the second metal foil:

and coating the surface adhesion layer of the at least one metal foil.

40. The manufacturing method of claim 34, wherein the second metal winding is wound on the surface of the first metal winding, and a via hole or a gap is formed during the winding process to allow the pin of the first metal winding to pass through.

41. The manufacturing method according to claim 34 or 40, wherein a third metal foil is cut to form a via or a void, the third metal foil is bent and coated on the surface of the second metal winding to form a third metal winding, and the pin of the first metal winding passes through the via or the void.