CN113851305A - Flat transformer containing peripheral magnetic device and manufacturing method thereof - Google Patents

Flat transformer containing peripheral magnetic device and manufacturing method thereof Download PDF

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Publication number
CN113851305A
CN113851305A CN202111148100.5A CN202111148100A CN113851305A CN 113851305 A CN113851305 A CN 113851305A CN 202111148100 A CN202111148100 A CN 202111148100A CN 113851305 A CN113851305 A CN 113851305A
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CN
China
Prior art keywords
magnetic
coil
transformer
cores
pcb
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202111148100.5A
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Chinese (zh)
Inventor
周铎源
侯勤田
欧阳过
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Apple Inc
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Shenzhen Sunlord Electronics Co Ltd
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Filing date
Publication date
Application filed by Shenzhen Sunlord Electronics Co Ltd filed Critical Shenzhen Sunlord Electronics Co Ltd
Priority to CN202111148100.5A priority Critical patent/CN113851305A/en
Publication of CN113851305A publication Critical patent/CN113851305A/en
Pending legal-status Critical Current

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • H01F27/26Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/266Fastening or mounting the core on casing or support
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/06Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2804Printed windings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/40Structural association with built-in electric component, e.g. fuse
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/42Circuits specially adapted for the purpose of modifying, or compensating for, electric characteristics of transformers, reactors, or choke coils
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/06Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
    • H01F2027/065Mounting on printed circuit boards
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2804Printed windings
    • H01F2027/2819Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit

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

Abstract

The invention discloses a flat transformer containing peripheral magnetic devices and a manufacturing method thereof, wherein the flat transformer comprises a PCB substrate, a PCB coil, a magnetic core and terminals; the PCB coil comprises a flat transformer coil and a magnetic device coil; the magnetic cores comprise flat transformer magnetic cores and magnetic device magnetic cores, and the number of the magnetic cores is correspondingly consistent with that of the PCB coils; mounting holes are respectively formed in the PCB substrate corresponding to the PCB coils, and the magnetic cores are respectively inserted into the mounting holes; the terminals include a planar transformer terminal and a peripheral magnetic device terminal. The product and the manufacturing method of the invention can reasonably plan and fully utilize the PCB substrate, greatly improve the utilization rate of the PCB substrate, avoid the waste problem of the PCB substrate in the prior art, or save the process of cutting the redundant part of the PCB substrate, and fully utilize the part of the PCB substrate needing to be cut in the prior art.

Description

Flat transformer containing peripheral magnetic device and manufacturing method thereof
Technical Field
The invention relates to the technical field of flat transformers, in particular to a flat transformer containing peripheral magnetic devices and a manufacturing method thereof.
Background
The conventional transformer is formed by winding a coil on a framework and then assembling the coil and a magnetic core, as shown in fig. 1, the manufactured product is large and high in size, and the heat dissipation is difficult due to the characteristics of the structure. The conventional PCB flat transformer can reduce the volume of the product, particularly the height of the product, but has several obvious disadvantages, one is that the utilization rate of the PCB material itself is not high in the manufacturing process of the product, for example, a part of the PCB material is often cut or wasted, which increases the process and/or direct cost. Secondly, the processing efficiency of the product is low. Thirdly, the subsequent use is not friendly enough, and the problems of inconvenient use are caused.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a flat-plate transformer containing peripheral magnetic devices, which comprises a PCB substrate, a PCB coil, a magnetic core and terminals, wherein the PCB substrate is provided with a plurality of through holes;
the PCB coil comprises at least one flat transformer coil and at least one magnetic device coil;
the magnetic cores comprise at least one flat transformer magnetic core and at least one magnetic device magnetic core, and the number of the magnetic cores is correspondingly consistent with that of the PCB coils;
mounting holes are respectively formed in the central parts of the PCB substrate corresponding to the PCB coils, and the magnetic cores are respectively inserted into the mounting holes;
the terminals include a planar transformer terminal and a peripheral magnetic device terminal.
The invention may also employ the following alternatives/preferences:
the planar transformer coil and the magnetic device coil are connected with each other on the PCB substrate.
The magnetic device magnetic cores are configured to be a set of magnetic cores, each magnetic core in the set of magnetic cores has a predetermined relative position relationship, and the predetermined relative position relationship corresponds to and is consistent with the relative position relationship of each mounting hole.
And filling adhesive materials between the magnetic cores in the set of magnetic cores, and keeping the preset relative position relationship through the adhesive materials.
The flat transformer coil is provided with a bonding pad, and the flat transformer terminal is arranged in the bonding pad in a soldering tin mode; the magnetic device coil is provided with a bonding pad, and the flat-plate transformer terminal is installed in the bonding pad in a soldering tin mode.
The invention also provides a manufacturing method of the flat-plate transformer containing the peripheral magnetic device, which comprises the following steps:
printing a PCB coil at a preset position on a PCB substrate, wherein the PCB coil comprises at least one flat transformer coil and at least one magnetic device coil;
arranging a mounting hole on the PCB substrate where the central part of each coil is positioned;
preparing an integrated set of magnetic cores, wherein the set of magnetic cores comprises at least one flat transformer magnetic core and at least one magnetic device magnetic core, and the number of the magnetic cores in the set of magnetic cores is correspondingly consistent with that of the PCB coils;
installing the set of magnetic cores into the installation holes, wherein the magnetic core center pillars of the planar transformer magnetic core are correspondingly inserted into the installation holes in the central part of the planar transformer coil to form a planar transformer, and the magnetic device magnetic cores are correspondingly inserted into the installation holes in the central part of the magnetic device coil to form peripheral magnetic devices;
terminals configuring the flat transformer and terminals of the peripheral magnetic devices are mounted, respectively.
The manufacturing method of the invention can also adopt the following optional/preferred scheme:
the connection of the planar transformer coil and the magnetic device coil is realized through a circuit printed on the PCB substrate.
The set of magnetic cores is made by filling an adhesive material between the magnetic cores.
The bonding material is epoxy resin.
The terminal for mounting the flat transformer comprises: firstly, arranging a bonding pad on the flat-plate transformer coil, and then installing a terminal in the bonding pad in a soldering tin mode; the terminal for mounting the peripheral magnetic device includes: firstly, a pad is arranged on the peripheral magnetic device coil, and then a terminal is installed in the pad in a soldering tin mode.
The beneficial effects of the invention include:
the product and the manufacturing method can reasonably plan and fully utilize the area of the PCB substrate, greatly improve the utilization rate of the PCB substrate, avoid the waste problem of the PCB substrate in the prior art, or save the process of cutting off the redundant part of the PCB substrate, and greatly improve the processing efficiency of the product.
The structure of the integrated magnetic core, namely the manufacturing method, is adopted, so that the assembly of the product is simple and efficient, the method of processing the transformer and the peripheral magnetic devices one by one in the prior art can be simplified into the simple process of inserting and installing the integrated magnetic core on the PCB substrate, and the processing efficiency of the product is further improved. In addition, when the product is used, the terminal can be directly connected according to the requirement, the peripheral magnetic device does not need to be reconfigured like the product in the prior art, and the product is very friendly and convenient for the subsequent use steps.
The product and the manufacturing method can integrate the peripheral magnetic devices in advance according to the specific production requirements, can also install the most economic and reasonable layout integrated peripheral magnetic devices, for example, a plurality of peripheral magnetic devices with different sizes and models are configured in advance to be made into standard products, and the subsequent products can selectively use the peripheral magnetic devices, so that a large amount of time cost such as design cost, mold opening cost, production line conversion and the like can be saved.
Drawings
Fig. 1 is a schematic structural diagram of a transformer formed by assembling components on a main transformer PCB substrate in the prior art.
Fig. 2 is a schematic structural diagram of a product after assembly and terminal configuration according to an embodiment of the present invention.
Fig. 3 is an exploded view of the product shown in fig. 2.
Fig. 4 is a schematic view of the structure of fig. 2 from another perspective.
Fig. 5 is a schematic structural view of the PCB substrate of fig. 2 with the PCB coils printed and mounting holes opened.
FIG. 6 is a schematic diagram of an integrated magnetic core of an embodiment.
Detailed Description
The invention will be further described with reference to the accompanying figures 1-6 and the specific embodiments. It should be emphasized that the following description is merely exemplary in nature and is not intended to limit the scope of the invention or its application. The background of the present invention may contain background information related to the problem or environment of the present invention and does not necessarily describe the prior art. Accordingly, the inclusion in the background section is not an admission of prior art by the applicant.
The magnetic device is an important component of the switching power supply, is a main device for completing energy storage and conversion, filtering and electrical isolation, and can affect the overall performance of the converter from multiple aspects. The transformer and the peripheral magnetic devices generally account for 30% of the total volume of the switching power supply, and if the multiple devices are independent of each other, the occupied volume is large, so that the layout of other elements on the circuit board can be seriously influenced, and the area of the PCB substrate is wasted. In principle, the inductive device and the transformer are both required to be composed of the coil winding and the magnetic core, and the coil windings of the inductive device such as the transformer, the inductor and the like are integrated on the same PCB substrate through advanced planning and reasonable layout, so that the space for using the PCB substrate is greatly reduced, resources are saved, and the convenience and the efficiency of the product during processing and use are improved.
Example one
As shown in fig. 2 to 5, a planar transformer including peripheral magnetic devices includes a PCB substrate 10, a PCB coil 40, a magnetic core, and terminals 30.
The PCB coil 40 includes at least one planar transformer coil and at least one magnetic device coil, specifically: the flat transformer coil 41 and the magnetic device coil 42, which are main transformer functional parts, are integrated in the same PCB coil 40, and a predetermined gap is left between the two parts of the coil, which at least plays a role of functional insulation. In addition, the planar transformer coil 41 and the magnetic device coil 42 are connected to each other on the PCB substrate 10, and the connection purpose is to conduct both the magnetic device and the planar transformer inside the PCB substrate, so as to achieve the purpose of reducing the magnetic device terminals, thereby reducing the processing cost and the material cost.
The magnetic cores comprise at least one flat transformer magnetic core (11, 12) and at least one magnetic device magnetic core (21, 22), and the number of the magnetic cores corresponds to the number of the PCB coils 40.
The PCB substrate is provided with mounting holes 50 corresponding to the central portions of the PCB coils, respectively, for example, a hole structure such as a cut center hole, and the center pillars of the magnetic cores are inserted into the mounting holes 50, respectively, that is, the center pillars of the planar transformer magnetic cores (11, 12) are inserted into the mounting holes 51 of the central portions of the planar transformer coils 41, and the center pillars of the magnetic device magnetic cores (21, 22) are inserted into the mounting holes 52 of the central portions of the magnetic device coils 42. Preferably, the center pillar of each magnetic core is further sleeved with filling foam, and penetrates through the mounting hole together with the magnetic core pillar, so as to be better integrated with the PCB substrate 10.
The terminals 30 include flat transformer terminals and peripheral magnetic device terminals. The flat transformer coil 41 is provided with a pad for mounting the configuration terminal 30, the flat transformer terminal is mounted in the pad by soldering, the magnetic device coil is provided with a pad for mounting the configuration terminal 30, and the magnetic device terminal is mounted in the pad by soldering. The structure and form of the terminal 30 may be PIN, lead wire, conductive copper foil, etc. The terminal 30 provided by the invention preferably adopts a PIN structure.
Preferably, the magnetic device cores are configured as a set of cores, and as shown in fig. 6, each of the cores in the set of cores has a predetermined relative positional relationship, and the predetermined relative positional relationship corresponds to a relative positional relationship of each of the mounting holes. Therefore, the magnetic cores can be assembled at one time, and the efficiency is improved. Each magnetic core in the set of magnetic cores can be processed in an integrated forming mode, and if the magnetic cores are combined type magnetic cores, the upper combined body and the lower combined body of each magnetic core are respectively and integrally formed. In addition, the magnetic cores in the set of magnetic cores may be filled with an adhesive material, and the predetermined relative positional relationship may be maintained by the adhesive material, and the adhesive material is preferably an epoxy resin. In addition, foam filled foam may also be used to help secure and isolate the PCB coil 40 and the various magnetic cores.
Example two
The manufacturing method of this embodiment may be used to manufacture the planar transformer with the peripheral magnetic device described in embodiment 1, and specifically, the manufacturing method of the planar transformer with the peripheral magnetic device includes the following steps:
printing a PCB coil at a preset position on a PCB substrate, wherein the PCB coil comprises at least one flat transformer coil and at least one magnetic device coil;
arranging a mounting hole on the PCB substrate where the central part of each coil is positioned;
preparing an integrated set of magnetic cores, wherein the set of magnetic cores comprises at least one flat transformer magnetic core and at least one magnetic device magnetic core, and the number of the magnetic cores in the set of magnetic cores is correspondingly consistent with that of the PCB coils;
installing the set of magnetic cores into the installation holes, wherein the magnetic core center pillars of the planar transformer magnetic core are correspondingly inserted into the installation holes in the central part of the planar transformer coil to form a planar transformer, and the magnetic device magnetic cores are correspondingly inserted into the installation holes in the central part of the magnetic device coil to form peripheral magnetic devices;
terminals configuring the flat transformer and terminals of the peripheral magnetic devices are mounted, respectively.
The connection between the planar transformer coil and the magnetic device coil can be realized through a circuit printed on the PCB substrate, so that the number of terminals of the magnetic device can be reduced, and the processing procedure and the cost are saved. The set of magnetic cores is made by filling adhesive material, preferably epoxy resin, between the magnetic cores, so as to better and more permanently maintain the relative positional relationship of the magnetic cores and the necessary gap. The terminal for mounting the flat transformer comprises: firstly, arranging a bonding pad on the flat-plate transformer coil, and then installing a terminal in the bonding pad in a soldering tin mode; the terminal for mounting the peripheral magnetic device includes: firstly, a pad is arranged on the peripheral magnetic device coil, and then a terminal is installed in the pad in a soldering tin mode.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several equivalent substitutions or obvious modifications can be made without departing from the spirit of the invention, and all the properties or uses are considered to be within the scope of the invention.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "preferred embodiments," "an example," "a specific example," or "some examples" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Various embodiments or examples and features of various embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction. Although embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the scope of the claims.

Claims (10)

1. A flat transformer containing peripheral magnetic devices is characterized by comprising a PCB substrate, a PCB coil, a magnetic core and terminals;
the PCB coil comprises at least one flat transformer coil and at least one magnetic device coil;
the magnetic cores comprise at least one flat transformer magnetic core and at least one magnetic device magnetic core, and the number of the magnetic cores is correspondingly consistent with that of the PCB coils;
mounting holes are respectively formed in the central parts of the PCB substrate corresponding to the PCB coils, and the magnetic cores are respectively inserted into the mounting holes;
the terminals include a planar transformer terminal and a peripheral magnetic device terminal.
2. The planar transformer including peripheral magnetic devices of claim 1, wherein said planar transformer coil and said magnetic device coil are interconnected on said PCB substrate.
3. The planar transformer with peripheral magnetic devices as claimed in claim 1, wherein said magnetic device cores are configured as a set of cores, each of said cores in said set of cores having a predetermined relative positional relationship corresponding to the relative positional relationship of each of said mounting holes.
4. A planar transformer including peripheral magnetic devices according to claim 3, wherein said set of cores is filled with an adhesive material therebetween, and said predetermined relative positional relationship is maintained by said adhesive material.
5. The planar transformer with peripheral magnetic devices as claimed in any one of claims 1 to 4, wherein said planar transformer coil is provided with a pad, and said planar transformer terminal is mounted in said pad by means of soldering;
the magnetic device coil is provided with a bonding pad, and the flat-plate transformer terminal is installed in the bonding pad in a soldering tin mode.
6. A manufacturing method of a flat transformer containing peripheral magnetic devices is characterized by comprising the following steps:
printing a PCB coil at a preset position on a PCB substrate, wherein the PCB coil comprises at least one flat transformer coil and at least one magnetic device coil;
arranging a mounting hole on the PCB substrate where the central part of each coil is positioned;
preparing an integrated set of magnetic cores, wherein the set of magnetic cores comprises at least one flat transformer magnetic core and at least one magnetic device magnetic core, and the number of the magnetic cores in the set of magnetic cores is correspondingly consistent with that of the PCB coils;
installing the set of magnetic cores into the installation holes, wherein the magnetic core center pillars of the planar transformer magnetic core are correspondingly inserted into the installation holes in the central part of the planar transformer coil to form a planar transformer, and the magnetic device magnetic cores are correspondingly inserted into the installation holes in the central part of the magnetic device coil to form peripheral magnetic devices;
terminals configuring the flat transformer and terminals of the peripheral magnetic devices are mounted, respectively.
7. The method of claim 6, wherein the connection between the planar transformer coil and the magnetic device coil is achieved by printed circuit on the PCB substrate.
8. The method of manufacturing a planar transformer including peripheral magnetic devices according to claim 6, wherein said set of magnetic cores is formed by filling an adhesive material between said magnetic cores.
9. The method of claim 8, wherein the bonding material is epoxy resin.
10. The method of manufacturing a planar transformer with peripheral magnetic devices as claimed in claim 6, wherein said mounting of said terminals of said planar transformer comprises: firstly, arranging a bonding pad on the flat-plate transformer coil, and then installing a terminal in the bonding pad in a soldering tin mode;
the terminal for mounting the peripheral magnetic device includes: firstly, a pad is arranged on the peripheral magnetic device coil, and then a terminal is installed in the pad in a soldering tin mode.
CN202111148100.5A 2021-09-29 2021-09-29 Flat transformer containing peripheral magnetic device and manufacturing method thereof Pending CN113851305A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202111148100.5A CN113851305A (en) 2021-09-29 2021-09-29 Flat transformer containing peripheral magnetic device and manufacturing method thereof

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202111148100.5A CN113851305A (en) 2021-09-29 2021-09-29 Flat transformer containing peripheral magnetic device and manufacturing method thereof

Publications (1)

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CN113851305A true CN113851305A (en) 2021-12-28

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH051205U (en) * 1991-06-20 1993-01-08 オリジン電気株式会社 Printed coil transformer and electric circuit
US20130106557A1 (en) * 2011-10-31 2013-05-02 Delta Electronics (Shanghai) Co., Ltd. Integrated magnetic element
CN203134536U (en) * 2012-09-17 2013-08-14 深圳Tcl新技术有限公司 Flat plate transformer, flat plate inductor and resonance circuit
CN107046770A (en) * 2017-04-13 2017-08-15 广东风华高新科技股份有限公司 Core structure and power model

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH051205U (en) * 1991-06-20 1993-01-08 オリジン電気株式会社 Printed coil transformer and electric circuit
US20130106557A1 (en) * 2011-10-31 2013-05-02 Delta Electronics (Shanghai) Co., Ltd. Integrated magnetic element
CN203134536U (en) * 2012-09-17 2013-08-14 深圳Tcl新技术有限公司 Flat plate transformer, flat plate inductor and resonance circuit
CN107046770A (en) * 2017-04-13 2017-08-15 广东风华高新科技股份有限公司 Core structure and power model

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Effective date of registration: 20240313

Address after: California, USA

Applicant after: APPLE Inc.

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Address before: 518110 Guanlan Industrial Park, DAFUYUAN Industrial Park, Guanlan street, Longhua District, Shenzhen City, Guangdong Province

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