DE10353529A1 - Transformer has metal core, and coil modules each having predetermined loop number of coils and encapsulator that comprises plastic material for encapsulating coils - Google Patents

Abstract

A transformer comprises a metal core, and coil modules each having a predetermined loop number of coils and an encapsulator that comprises a plastic material for encapsulating the coils. A portion of the coils of the coil modules functions as primary coils. While, other portion of the coils of the coil modules functions as secondary coils. The coil modules are stacked one on another. Each coil module surrounds the metal core. An Independent claim is also included for a method of manufacturing the transformer, comprising selecting the coil modules made in advance, where the selection of the coil modules is made according to the loop number of coils of the coil modules; and stacking the coil modules one on another to surround the metal core.

Description

Territory of invention

The present invention relates to Transformers. In particular, the present invention relates Coil modules and transformers that use the coil modules.

Coil elements are commonly used in Transformers and other electronic devices used. However takes winding coils takes too much time and becomes too complicated. Moreover could implicit hazards due to careless manufacture or use like random fires or Electric shocks occur.

1 (a) shows a schematic cross-sectional view of a conventional transformer 10 and coils attached to it. The transformer 10 has a bobbin 101 , Pencils 102 , a metal core 103 , Insulating tapes 104 . 105 and coils 106 ,

The bobbin 101 carries the pens 102 and the metal core 103 , The insulating tapes 104 are used such that the positions of the coils 106 follow certain security standards. The spools 106 are wound one after the other until all the necessary bobbins 106 on the bobbin 101 are installed. Every coil 106 has two wires that connect to other elements in certain applications with the pin 102 are connected. The bands 105 are provided such that the coils 106 the different groups are kept at a suitable distance from each other.

1 (b) shows a schematic cross-sectional view of another conventional transformer 11 , Similarly, the transformer has 11 a bobbin 111 , Pencils 112 , a core 113 , Insulating layers 114 and coils 116 ,

The bobbin carries the pens 112 , the core 113 and the insulation layers 114 , The spools 116 are on the bobbin 111 wrapped one layer at a time. In this example, the four coil layers 1161 . 1162 . 1163 and 1164 different coil windings to perform two different electrical voltage transformations. The coil layers 1161 and 1163 are used to act as the primary coils of the transformer 11 to serve for input of voltage and the layers 1162 and 1163 are used to act as secondary coils of the transformer 11 serve to output the resulting electrical voltage.

The winding process in both examples according to the 1 (a) and 1 (b) are slow because the coil wires are wound one layer at a time. Inattentive factory personnel can make mistakes in the number of windings for some layers. However, windings from the other layers must first be unwound before the number of windings of the defective layer can be corrected.

Such winding processes are also imprecise. In the example of 1 (a) is the thickness of the tapes 104 and 105 difficult to control. In 1 (b) the insulating layers take up unnecessary space and increase the size of the transformer 11 , Also, the coil wires can have different lengths, even if the coil windings are the same if the coils are not properly wound. In addition, the coils can easily break during winding, especially if the bobbin structure is like that in FIG 1 (b) structure shown 111 is complicated.

Therefore, there are still many problems in the manufacture of transformers.

SUMMARY OF INVENTION

According to one aspect of the present Invention, a coil module is disclosed. The coil module has a conductive wire and an insulating encapsulation. The senior Wire has a section wound in coils. The number of turns the coil is selected from a predetermined group. The Coils form a coil opening. The insulating encapsulation encapsulates the coils and forms one Core opening. An outline of the core opening lies within the coil opening. To heat dissipation will improve additionally a certain amount of heat conductive Powder for encapsulation added.

According to another aspect of Present invention discloses a transformer, the such Coil modules used. In the embodiment a metal core is provided to manufacture the transformer. Next coil modules of the required coil windings are selected. This Coil modules are installed so that the core opening of the Coil module surrounds the metal core. In addition, these coil modules arranged in a stack. The coils of two neighboring coil modules through the insulating encapsulation of two adjacent coil modules Cut. To meet certain requirements, there are also a number of coil modules connected in parallel or in series in the transformer.

According to another aspect of In the present invention, another type of coil module is provided, and this type of coil module can be used in transformers become. Several such coil modules are not stacked vertically stacked. Instead, these coil modules are essentially the same level arranged horizontally, and surround the outer coil modules the inner coil modules.

According to a further aspect of the present invention, they are vertical and horizontal ordered coil modules mixed together in a transformer.

According to another aspect of The present invention is a method for manufacturing coil modules disclosed. First is a metal film by a stamping process or another mechanical Pattern the process. Then the one with the pattern provided metal foil to the aforementioned conductive line of Coil modules folded.

The process of making Transformers is therefore simplified and is flexible. Compared the coil modules become the state of the art directly without arrangement additional insulation stacked so the height of the transformer is reduced. Also the height of the transformer even less if the coil modules are arranged horizontally. The insulating encapsulation protects also the coils from damage during manufacture or use. Therefore, the present creates Invention a good solution for the Coil winding in transformers, which is flexible quality improved and leads to low manufacturing costs.

The accompanying drawings are for a better one understanding the invention provided and form part of this description. The drawings represent exemplary embodiments the invention and together with the description serve to explain the Principles of the invention. Show it

1 (a) a schematic cross-sectional view of a conventional transformer;

1 (b) is a schematic cross-sectional view of another conventional transformer;

2 (a) is a schematic view of an embodiment of a coil module according to the present invention;

2 B) a side view of 2 (a) ;

3 (a) to 3 (c) schematic representations of steps for installing a coil module according to the present invention;

4 a flow diagram for installing coil modules according to the present invention;

5 (a) is a schematic view of a portion of a transformer using coil modules according to the present invention;

5 (b) a top view of 5 (a) ;

6 (a) . 6 (b) . 6 (c) . 6 (d) . 6 (e) . 6 (f) and 6 (g) schematically other embodiments of coil modules according to the present invention;

7 (a) schematically coil modules according to the present invention in series connection;

7 (b) schematically coil modules according to the present invention in parallel connection;

8 (a) a coil pattern;

8 (b) a conductive layer;

8 (c) a coil module, manufactured after 8 (b) according to the coil pattern of 8 (a) ;

9 a flowchart for the manufacture of the coil module of 8 (c) ; and

10 schematically shows another embodiment of a transformer according to the present invention.

DESCRIPTION THE PREFERRED EMBODIMENTS

First preferred embodiment

2 (a) and 2 B) show different views of a coil module 20 according to the present invention. 2 B) is a side view of 2 (a) , The coil module 20 has a conductive wire 201 , A wire insulated with enamel is an example of the conductive wire 201 , The conductive wire has a section that is in coils 2011 a number of turns is wound, and the number of turns is selected from a predetermined group. In this example, the number of turns of the coils is 2011 4, which is selected from a predetermined group of (2.5, 3, 4, 5, 10, 20}. The designer can select the predetermined group. With such a construction, the manufacturers can produce a large number of coil modules with certain number of turns in advance to keep costs down, and certain types of such coil modules are manufactured as standard elements for other manufacturers to build transformers based on their requirements.

In addition to the conductive wire 201 owns the coil module 20 also an insulating encapsulation 202 , The insulating encapsulation 202 encapsulates the coils 2011 made of conductive wire 201 on. The spools 2011 form a coil opening 2012 , In addition, the insulating encapsulation forms 202 a core opening 2021 , and the outline 2022 the core opening 2021 lies within the coil opening 2012 ,

In this version, the insulating encapsulation 202 be made of plastic. Thermoplastic or other insulating materials are used to make the forms of the insulating encapsulation 202 used. For example, a winding machine or a punching machine can be used to wind the coils 2011 of the coil module 20 to shape. Heat is generated during the operation of the transformer and usually prevents encapsulation 202 a heat dissipation. To solve this problem, a lot of thermally conductive powder, for example ceramic powder, is placed in the encapsulation 202 mixed. Such coil modules with good heat dissipation properties can be used in a printed circuit board or other applications, as mentioned below.

The 3 (a) to 3 (c) show an installation of the coil modules 20 into a transformer. A metal core 31 is based 32 attached. The coil module 20 is around the metal core 31 arranged through the core opening 2021 so that the outline 2022 the core opening 2021 the metal core 31 surrounds.

Usually a transformer has two or more coils. The coils for inputting voltage are called the primary coils. The coils for outputting a voltage resulting from an electromagnetic reaction are called the secondary coils. By setting the number of windings of the primary coils and the secondary coils, a transformer is obtained that meets a specific requirement. The coil modules 20 with different numbers of windings can be manufactured in advance. For example, coil modules 20 of the winding numbers 4, 5, 6, ..., 100 manufactured and tested. The winding process is dramatically simplified. Winding in a transformer with specific requirements only requires the selection of coil modules 20 with necessary winding numbers and the installation of these coil modules 20 in the transformer or a printed circuit board.

In summary, an embodiment for manufacturing a transformer has the following steps with reference to the flow chart of FIG 4 on. First, the coil modules 20 prepared (step 42). The coil modules 20 with special numbers of windings are produced in advance as standard elements. Next is the metal core 31 , as in 3 (b) shown, created (step 44). Then the coil modules with the necessary number of windings are selected and installed in the transformer (step 46), so that the outline 2022 the core opening 2021 of the coil modules the metal core 31 surrounds as in 3 (a) to 3 (c) is shown.

The coil modules 20 are arranged as a stack when installed in the transformer, as in 5 (a) and 5 (b) is shown. 5 (b) is a top view of 5 (a) , The sink 2011 of the coil module 20 is through the insulating encapsulation 202 encapsulated. That is why the coils 2011 every coil 20 through the insulating encapsulation 202 Cut. In other words, the distance between the coils 2011 two adjacent coil modules 20 is determined by the thickness of the insulating encapsulation 202 of the two adjacent coil modules 202 certainly.

In addition, the coil module has 20 just a cover on the coils 2011 , To prevent the non-encapsulated parts of the conductive wires 201 two adjacent coil modules 20 get too close, the edges of adjacent coil modules 20 in different directions, like in 5 (a) and 5 (b) is shown. In this example, the edges of the coil modules are therefore 20 the primary coils arranged in a different direction than the edges of the coil modules 20 of the secondary coils. However, the edges of the primary coil and the secondary coils can be arranged in the same direction if the coil modules 20 according to the present invention can be used for a larger transformer or the distance between the conductive wires 201 is sufficient.

At the in 2 (a) The example shown is each winding of the coils 2011 of the coil module 20 arranged on essentially the same level. In other words, each winding extends from the coil opening 2011 to avoid overlap with another winding. Such a construction reduces the height of each coil module and therefore the height of the transformers. Nevertheless, there is also an overlapping arrangement of the windings of the coils 2011 a coil module 20 with others also within the scope of the present invention.

Also the shape of the insulating encapsulation 202 , the core opening 2021 and the coils 2011 in 2 (a) selectable according to the needs of the designer. The insulating encapsulation 610 . 620 . 630 , the core openings 611 . 621 . 631 and the coils 612 . 622 . 632 are variants of the corresponding insulating encapsulation 201 , the core openings 2021 and the coils 2011 in 2 (a) ,

In order to meet certain requirements, the windings of the conductive wire in the coil module also overlap one another as a stack. Of course, these windings can be spirally wound at the same time in every horizontal plane. 6 (d) and 6 (e) show such coil modules. An encapsulation 640 encapsulates a coil 642 one, and encapsulation 640 has a core opening for installing a core.

In addition, the number of conductive wires 20 Selectable according to the designer's needs and does not need a single conductive wire 201 to be restricted, as shown in the previous example. For example, a group of primary coils and secondary coils is embedded in a coil module 20 within the scope of the present invention. In addition, any number of the conductive wire may be encapsulated by an encapsulation to form a coil module. For example, encapsulates in 6 (f) the encapsulation 650 five independent coils one that consist of five independent conductive wires 642 consist. 6 (g) shows a transformer with the in 6 (f) coil modules shown.

In addition, they are in 2 (a) and 5 (a) coil modules shown 20 stacked directly because of the insulating encapsulation 202 the spools 2011 encapsulates. However, the insertion of certain insulating elements, such as an insulating ring, lies between the coil modules 20 also within the scope of a coil module stack invention.

In addition, the number of windings and the lead wire properties of the coil module 20 predetermined so that the cost is reduced by mass production. In addition, a series connection or parallel connection of the coil modules is released 20 the problem that special types of coil modules 20 are not available on the given list.

7 (a) shows a series connection of coil modules 71 . 72 to achieve a higher number of coils, and 7 (b) shows a parallel connection of coil modules 73 . 74 for coils to maintain a higher voltage or prevent a skin effect when the frequency is reduced.

Second preferred execution

The 8 (a) . (B) . (C) show another method of implementing the coil modules according to the present invention, and at 9 it is a flowchart that shows a sequence of such a method.

First, a coil pattern is determined according to a requirement. 8 (a) shows a coil pattern example that has eight turns of coils. Next, conductive material such as copper, aluminum, or another conductive alloy is selected (step 901). A punch press is then used to produce a conductive strip according to the associated coil pattern (step 902). The conductive strip has a coil section with a certain number of coil windings. In 8 (a) there are eight coil sections 801 . 802 . 803 . 804 . 805 . 806 . 807 and 808 , When the coil sections are folded as a stack, a coil opening is formed through the folded coil sections. In other words, the conductive strip is used as the conductive wire of the coil modules in the first preferred embodiment.

Next are the eight coil sections 801 to 808 folded as a stack (step 903), and insulation material 81 , e.g. B. an insulating spacer, is between the eight coil sections 801 to 808 added as in 8 (c) is shown. Then an encapsulation 82 for encapsulating the eight coil sections 801 to 808 used to form a coil module.

It is also shown in Example of the conductive strip folded as a stack around the coils to form in the coil module. However, the conductive strip can also are punched to form coils that are directly wound spirally are. Therefore in such a situation it is not necessary fold the conductive strip to form the coil modules.

Of course, a certain amount of heat-conductive powder, for example ceramic powder, can be used for encapsulation 82 be added for heat dissipation. In addition, more than one conductive strip can be encapsulated in a coil module.

The previously described manufacturing process is particularly efficient for mass production of transformers, the specific specifications suffice. The cost will be reduced, the manufacturing speed will elevated, while high quality of the products is retained.

Third preferred embodiment

In the two previously described embodiments the coil modules around the coil as the main units of the transformer stacked. However, the coil module can also be essentially horizontal be arranged in the same plane, while the coil modules in concentric Circles.

Reference is made below to 10 that have an external coil module 122 and an inner coil module 124 shows that around the nucleus 126 are arranged in concentric circles. Such an arrangement provides a further improvement in the height of the transformers. This property is particularly important for various electronic devices with strict height restrictions.

Of course, more than two coil modules can be arranged in concentric circles. Presently the number of coil modules only by the specifications of the transformers certainly. In other words, more than two coil modules can be in the Be arranged essentially on the same level, with the outer coil modules surround the inner coil modules.

In addition, all variants and an implementation process can also in this embodiment be used. For example, through a stamping process manufactured conductive strips are used in this embodiment.

In summary, the previous one Description read from the present invention that at least has the following advantages. First, reduce flexibility and simplicity of the coil modules significantly increases the cost of manufacture of transformers. Second, the coils are insulated by the Encapsulation protected, and damage during the Manufacturing of the transformer is avoided. Third, the Distance between the coils in two adjacent coil modules precise and easy by adjusting the thickness of the insulating encapsulation of two adjacent coil modules checked. Also the height of Transformers reduced because the coil modules are stacked directly can be.

It is obvious to the person skilled in the art that various modifications and variations can be made in the structure of the present invention without departing from the scope and spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided that they fall within the scope of the following claims and their equivalents.

Claims (27)

Transformer with a metal core; and more Coil modules, each of which coil module has a certain number of windings of coils and an encapsulation comprising plastic material for encapsulating the coils; being a section of the Coils of the plurality of coil modules are provided as primary coils while one another section of the coils of the plurality of coil modules as secondary coils is provided, and the plurality of coil modules are stacked one above the other and each coil module surrounds the metal core. The transformer of claim 1, wherein the coils each coil module has a wound section of at least one have conductive wire. The transformer of claim 1, wherein the coils each coil module a coil-shaped Have section of at least one conductive wire. The transformer of claim 1, wherein the coils are arranged essentially in the same plane. The transformer of claim 1, wherein the coils are arranged as a stack of coils. The transformer of claim 1, wherein a group of coil modules is connected in series or in parallel. The transformer of claim 1, wherein the insulating Encapsulation with thermally conductive material is mixed. The transformer of claim 7, wherein the thermally conductive Material has ceramic powder. A transformer according to claim 1, in which a plurality conductive wires provided in a coil module and the coils of these conductive Wires through the encapsulation is separate. Transformer with: a metal core; and more Coil modules, each of which coil module has a certain number of windings of coils and an encapsulation comprising plastic material for encapsulating the coils; being a section of the Coils of the plurality of coil modules are provided as primary coils while one another section of the coils of the plurality of coil modules as secondary coils is provided, and the plurality of coil modules in the metal core surrounding concentric circles are arranged. The transformer of claim 10, wherein the Spools each coil module at least one wound section have a conductive wire. The transformer of claim 10, wherein the Coils of each coil module have at least one coil-shaped section have a conductive wire. The transformer of claim 10, wherein the Coils are arranged essentially in the same plane. The transformer of claim 10, wherein the Coils are arranged as a stack of coils. The transformer of claim 10, wherein one Group of coil modules is connected in series or in parallel. The transformer of claim 10, wherein the insulating encapsulation with thermally conductive Material is mixed. The transformer of claim 16, wherein the thermally conductive Material has ceramic powder. The transformer of claim 10, wherein a plurality conductive wires provided in a coil module and the coils of these conductive wires through the encapsulation is separate. Coil module with: a predetermined number of windings of coils, the predetermined number of coils from a predetermined Group selected is; and an insulating encapsulation comprising plastic material to encapsulate the coils and separate the coils from one another Contact with other coils of another neighboring coil module, if several coil modules are installed in one transformer, wherein a section of the plurality of coil modules as primary coils is provided while another section of the plurality of coil modules as secondary coils is provided. Process for manufacturing a transformer, with the steps: to provide a metal core; several To select coil modules in advance, wherein each coil module has a number of coils and one Insulating encapsulation for encapsulation comprising plastic material of the coils and the selection of the coil modules according to the number of windings the coils of the multiple coil modules are hit; and the several coil modules one above the other stack to enclose the metal core, with a portion of the Coils of the multiple coil modules as primary coils and another section the coils of the plurality of coil modules are provided as secondary coils. The method of claim 20, further comprising the step of to produce a group of coil modules, with each group passing through the number of windings of the coils embedded in a coil module is differentiated. 22. The method of claim 21, wherein during the Manufacturing the groups of the coil modules the coil in each coil module is arranged in a stack of coils. The method of claim 21, wherein during the Manufacturing the groups of coil modules the coils in each coil module obtained by winding at least one conductive wire. 22. The method of claim 21, wherein during the Manufacturing the groups of the coil modules the coils in each coil module form a section of at least one conductive strip. The method of claim 24, wherein the section of the conductive strip is folded around the coils in each coil module to build. The method of claim 24, wherein during the Manufacture of groups of coil modules through the conductive strips Stamping of a conductive material made according to a coil pattern becomes. 22. The method of claim 21, wherein during the Production of the groups of coil modules in the thermally conductive material Encapsulation is mixed.