EP1091369A2 - Niederprofiltransformator und Herstellungsverfahren eines Niederprofiltransformators - Google Patents

Niederprofiltransformator und Herstellungsverfahren eines Niederprofiltransformators Download PDF

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Publication number
EP1091369A2
EP1091369A2 EP00308677A EP00308677A EP1091369A2 EP 1091369 A2 EP1091369 A2 EP 1091369A2 EP 00308677 A EP00308677 A EP 00308677A EP 00308677 A EP00308677 A EP 00308677A EP 1091369 A2 EP1091369 A2 EP 1091369A2
Authority
EP
European Patent Office
Prior art keywords
electrical
base member
termination
low profile
transformer
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.)
Withdrawn
Application number
EP00308677A
Other languages
English (en)
French (fr)
Other versions
EP1091369A3 (de
Inventor
Galliano Riccardo Busletta
William Lonzo Woods, Jr.
Matthew Anthony Wilkowski
Robert Joseph Roessler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nokia of America Corp
Original Assignee
Lucent Technologies Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Lucent Technologies Inc filed Critical Lucent Technologies Inc
Publication of EP1091369A2 publication Critical patent/EP1091369A2/de
Publication of EP1091369A3 publication Critical patent/EP1091369A3/de
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2823—Wires
    • H01F27/2828—Construction of conductive connections, of leads
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F27/292—Surface mounted devices

Definitions

  • the present invention is directed to electrical transformers, and especially to electrical transformers presenting a low profile in their assembled state.
  • the invention also contemplates a method for making a low profile transformer.
  • transformers are fabricated by winding wire on a plastic bobbin, or header, and terminating those windings at the bobbin. Thereafter, the bobbin-winding unit is assembled with a magnetic core to enhance the transformer's electrical properties, as is well known in the art.
  • a bobbin, or header has a significant impact on the height of the transformer product. Up to fifty per cent of the height of the finished transformer can be attributable to the bobbin or header being used to support the windings.
  • transformers Another problem has been encountered as designers strive to make transformers smaller: the cores become physically less robust and are prone to fractures. Yet another consequence of smaller transformers occurs when the decrease in size is achieved by reducing the cross-section of the transformer core. Operating a transformer with a lesser cross-section in its core causes greater core loss power dissipation and deterioration of initial electrical properties, such as inductive flux-carrying capacity. The reduced cross section, or area, of the winding also reduces inductance and limits the available power the magnetic device can deliver.
  • the preferred embodiment of the present invention is a low profile magnetic device, preferably in the form of an electrical transformer, comprising at least two electrical windings and a ferromagnetic base member.
  • the base member is preferably an integral construction presenting a core structure and a plurality of termination structures.
  • the electrical windings are arrayed about the core structure and present a plurality of lead structures which are attached with the termination structures for electrical attachment in a circuit.
  • the invention also includes a method for making the low profile magnetic device.
  • the method of the present invention for making the low profile transformer having an electrical winding structure including at least electrical windings and a plurality of termination structures; and a base member having a plurality of termination sites comprises the steps of: (a) assembling the electrical winding structure and the base member; and (b) during the assembling, attaching the plurality of electrical termination structures with at least some of the plurality of termination sites to present a plurality of electrical termination loci for connection within an electrical circuit.
  • the apparatus of the present invention has an insulative layer on the base member.
  • the insulative layer is a coating of insulative material, such as an epoxy material or paralene.
  • the preferred embodiment of the present invention includes a ferromagnetic core and bondable wire wound rings or a planar sheet of copper foil.
  • the wire round rings or sheet copper foil are assembled directly with the core without any intervening bobbin or header.
  • the wire wound rings are insulated from each other and have their ends stripped to expose the wire to facilitate electrical connection.
  • the copper foil preferably has an insulating spacer above and below the copper foil.
  • the only physical connection between the wire wound rings or foil and the ferromagnetic base, or core, in the preferred embodiment is the winding of the stripped wire ends or foil about discrete mounting posts of the base member.
  • the core is insulated, preferably with an insulating coating of paralene.
  • a lid preferably ferromagnetic, may be applied to improve the physical integrity of the package, as well as to enhance the flux integrity of the transformer product.
  • a further object of the present invention is to provide a low profile transformer which does not need to occupy extra real estate in circuitry in order to achieve its lower height.
  • Yet a further object of the present invention is to provide a low profile transformer which does not sacrifice robustness of the part or increase losses of the part.
  • FIG. 1 is an exploded view of the preferred embodiment of the present invention in unassembled form.
  • a transformer assembly 10 includes a base member 12, an electrical winding structure 14, and a cover 16.
  • Base member 12 includes a centrally situated magnetic flux concentrating structure, or core 18 extending from a foundation 20. Also extending from foundation 20 are a plurality of substantially similar support posts 22, 24, 26, 28. An annular channel 13 is thus established intermediate core 18 and support posts 22, 24, 26, 28. Preferably annular channel 13 is appropriately dimensioned to receive electrical winding structure 14 during assembly of transformer assembly 10.
  • Each support post 22, 24, 26, 28 includes an integrally formed pair of termination sites.
  • support post 22 includes termination sites 30, 32; support post 24 includes termination sites 34, 36; support post 26 includes termination sites 38, 40; and support post 28 includes termination sites 42, 44.
  • An alignment, or orientation ridge 46 is also included extending from foundation 20 to aid in orientation or alignment of the transformer after assembly.
  • base member 12 is constructed as an integral piece of ferromagnetic material.
  • Base member 12 preferably is insulated from other components of transformer 10.
  • base member 12 is coated, or encapsulated, with a deposited insulative coating, such as an epoxy or paralene coating.
  • base member 12 may have only areas proximate to termination sites 30, 32, 34, 36, 38, 40, 42, 44 coated with an insulating material.
  • base member 12 need not be constructed of ferromagnetic material, and preferably would not be constructed of such material.
  • core 18 may be used merely as a positioning structure to aid in orienting electrical winding structure 14 during assembly, or core 18 may be eliminated.
  • Electrical winding structure 14 includes three distinct wire coils substantially concentrically wound in a cylindrical winding 15 having a central aperture 17. Discrete wire coils are not shown in detail in Fig. 1 because the winding of multiple coils in substantially concentric fashion is known in the art, and any such known winding method may be employed in the winding of electrical winding structure 14. In fact, there may be any amount of two or more discrete coils in electrical winding structure 14, depending upon the nature of transformer being constructed. The structure and method of the present invention contemplate inclusion of transformers having two or more windings.
  • Electrical winding structure 14 includes first coil electrical termination structures 50, 52, second coil electrical termination structures 54, 56, and third coil electrical termination structures 58, 60 for effecting electrical connection with the various coils included in electrical winding structure 14.
  • the preferred form of electrical termination structures 50, 52, 54, 56, 58, 60 is bare wire solder-dipped leads.
  • Cover 16 is preferably constructed of material similar to the material used to fabricate base member 12. Cover 16 is proportioned to be substantially coextensive with the expanse of foundation 20. When transformer 10 is assembled, cover 16 is attached with base member 12 at support posts 22, 24, 26, 28.
  • electrical winding assembly 14 is situated lying generally adjacent to foundation 20 in substantially concentric relation with respect to core 18 with core 18 within aperture 17, surrounded by electrical winding structure 14.
  • Electrical termination structures 50, 52, 54, 56, 58, 60 are fastened with individual termination sites 30, 32, 34, 36, 38, 40, 42, 44, preferably by winding electrical termination structures 50, 52, 54, 56, 58, 60 about termination sites 30, 32, 34, 36, 38, 40, 42, 44, as will be described in greater detail hereinafter in connection with Figs. 2 ⁇ 4.
  • FIG. 2 is a top plan view of the preferred embodiment of the present invention in assembled form with the top removed.
  • electrical winding structure 14 is situated lying generally adjacent foundation 20. Aperture 17 is concentrically located about core 18; electrical winding structure 14 surrounds core 18.
  • Electrical termination structure 50 is fastened with termination site 30, electrical termination structure 52 is fastened with termination site 32, and electrical termination structure 54 is fastened with termination sites 34, 36. All fastening is preferably effected by winding the respective electrical termination structure 50, 52, 54 about the respective termination site 30, 32, 34, 36. In the case of electrical termination structure 54, the fastening is made to both termination sites 34, 36 simply by winding electrical termination structure 54 about both termination sites 34, 36.
  • termination sites 34, 36 are electrically common in the assembled transformer illustrated in Fig. 2.
  • electrical termination structure 56 is wound-fastened in electrical common with termination sites 38, 40.
  • Electrical termination structure 58 is wound-fastened with termination site 42, and electrical termination structure 60 is wound-fastened with termination site 44.
  • the fastening of electrical termination structures 50, 52, 54, 56, 58, 60 with termination sites 30, 32, 34, 36, 38, 40, 42, 44 may be effected in any combination of electrical termination structures and termination sites, or a combination of any subset of electrical termination structures and termination sites.
  • the particular connections illustrated in Fig. 2 are for the purpose of illustration of the preferred embodiment of the invention only, and such connections are not intended to limit the scope of the invention in any way.
  • FIG. 3 is a top plan view of the preferred embodiment of the present invention in assembled form with the top installed.
  • electrical termination structures 50, 52, 54, 56, 58, 60 are fastened with termination sites 30, 32, 34, 36, 38, 40, 42, 44 as described in connection with Fig. 2 above.
  • Cover 16 is affixed to base member 12 (base member 12 is situated beneath-cover 16 and not visible in Fig. 3).
  • a label 19 is illustrated as being affixed to cover 16, preferably by adhesive.
  • FIG. 4 is a side view of the preferred embodiment of the present invention in assembled form, taken along section 4 ⁇ 4 in Fig. 3.
  • cover 16 is shown resting atop support posts 22, 24, 26, 28 (only support posts 26, 28 are visible in Fig. 4).
  • the preferred method for affixing cover 16 to base member 12 at support posts 22, 24, 26, 28 is by adhesive. Other affixation methods or materials are also acceptable.
  • Fig. 4 further shows another feature of the present invention not readily observable from Figs. 1 ⁇ 3.
  • transformer 10 presents contact areas suitable for surface mounting on a printed wiring board or similar substrate.
  • those contact areas are identified as contact areas 64, 66, 68.
  • Contact areas 64, 66, 68 present a generally rough planar area by the faces of windings of electrical termination structures 56, 58, 60.
  • the preferred mounting method for attaching transformer 10 within an electrical circuit on a printed wiring board is using infrared (IR) reflow solder technology. Such IR reflow solder mounting will fill in "rough" areas between windings of electrical termination structures 56, 58, 60 and firmly seatingly attach transformer 10 to a printed wiring board.
  • IR infrared
  • Electrical termination structures 50, 52, 54 cooperating with termination sites 30, 32, 34, 36 (not shown in Fig. 4) will similarly provide contact areas and effect firm seating of transformer 10 during mounting upon a printed wiring board.
  • Other connection technologies will similarly accommodate the structure of transformer 10 for providing solid seating during attachment within a circuit, such as vapor phase reflow solder, conductive epoxy, and similar mounting technologies.
  • FIG. 5 is a flow diagram illustrating the preferred embodiment of the method of the present invention.
  • the process is begun by obtaining an electrical winding structure, such as electrical winding structure 14 of Figs. 1 ⁇ 4, as indicated by block 70.
  • the electrical winding structure obtained pursuant to block 70 includes at least two windings and a plurality of termination structures for electrically connecting with the respective electrical windings.
  • the electrical winding structure is fabricated in a substantially rigid form to facilitate handling during assembly.
  • the method of the present invention also involves obtaining a base member, such as base member 12 of Figs. 1 ⁇ 4, as also indicated by block 70.
  • the base member may be cast or it may be prepared by other suitable manufacturing methods.
  • the transformer to be fabricated is to be an air core transformer, then the base member may be molded.
  • the base has a plurality of termination sites.
  • the base member is constructed as an integral piece of ferromagnetic material.
  • the base member preferably is insulated from other components of the transformer.
  • the base member is coated, or encapsulated, with a deposited insulative coating, such as an epoxy or paralene coating.
  • the winding structure is situated generally adjacent the base member. If the base member has a flux concentrating structure, the winding structure is situated with respect to the base member to advantageously interact with the flux concentrating structure during operation of the transformer.
  • An example of such a flux concentrating structure is core 18 in the transformer illustrated in Figs. 1 ⁇ 4.
  • the plurality of electrical termination structures are attached with the plurality of termination sites, as indicated by block 76. Preferably the termination is effected according to a pattern required for proper mounting of the transformer in assembled form within a circuit, such as a circuit on a printed wiring board.
  • a cover is attached, as indicated by block 78, to complete the assembly of the transformer.
  • a preferred technology for attaching the cover is to adhesively attach the cover to the base member in a manner capturing the winding structure intermediate the base member and the cover.
EP00308677A 1999-10-07 2000-10-03 Niederprofiltransformator und Herstellungsverfahren eines Niederprofiltransformators Withdrawn EP1091369A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US414408 1995-03-31
US41440899A 1999-10-07 1999-10-07

Publications (2)

Publication Number Publication Date
EP1091369A2 true EP1091369A2 (de) 2001-04-11
EP1091369A3 EP1091369A3 (de) 2002-04-17

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EP00308677A Withdrawn EP1091369A3 (de) 1999-10-07 2000-10-03 Niederprofiltransformator und Herstellungsverfahren eines Niederprofiltransformators

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EP (1) EP1091369A3 (de)
JP (1) JP2001143940A (de)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202008004315U1 (de) * 2008-03-29 2009-08-06 Neosid Pemetzrieder Gmbh & Co. Kg Induktives Bauelement, insbesondere Antenne
EP2227815A2 (de) * 2007-06-15 2010-09-15 Cooper Technologies Company Abgeschirmte, magnetische miniaturkomponente
WO2014116917A1 (en) * 2013-01-25 2014-07-31 Vishay Dale Electronics, Inc. A low profile high current composite transformer
CN110914937A (zh) * 2017-05-29 2020-03-24 稀薄能源有限公司 薄变压器及其制造方法
US10854367B2 (en) 2016-08-31 2020-12-01 Vishay Dale Electronics, Llc Inductor having high current coil with low direct current resistance
US10998124B2 (en) 2016-05-06 2021-05-04 Vishay Dale Electronics, Llc Nested flat wound coils forming windings for transformers and inductors
US11948724B2 (en) 2021-06-18 2024-04-02 Vishay Dale Electronics, Llc Method for making a multi-thickness electro-magnetic device

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2163992B1 (de) * 1971-12-22 1973-06-14 Siemens Ag, 1000 Berlin U. 8000 Muenchen Halterungsvorrichtung fur zur Ver bindung mit einer Leiter oder Schicht schaltungsplatte bestimmte Bauelemente
US5212345A (en) * 1992-01-24 1993-05-18 Pulse Engineering, Inc. Self leaded surface mounted coplanar header
JPH0817659A (ja) * 1994-06-29 1996-01-19 Tamura Seisakusho Co Ltd 薄型トランス
DE19812836A1 (de) * 1998-03-24 1999-09-30 Pemetzrieder Neosid Induktives Miniatur-Bauelement für SMD-Montage

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2163992B1 (de) * 1971-12-22 1973-06-14 Siemens Ag, 1000 Berlin U. 8000 Muenchen Halterungsvorrichtung fur zur Ver bindung mit einer Leiter oder Schicht schaltungsplatte bestimmte Bauelemente
US5212345A (en) * 1992-01-24 1993-05-18 Pulse Engineering, Inc. Self leaded surface mounted coplanar header
JPH0817659A (ja) * 1994-06-29 1996-01-19 Tamura Seisakusho Co Ltd 薄型トランス
DE19812836A1 (de) * 1998-03-24 1999-09-30 Pemetzrieder Neosid Induktives Miniatur-Bauelement für SMD-Montage

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 1996, no. 05, 31 May 1996 (1996-05-31) & JP 08 017659 A (TAMURA SEISAKUSHO CO LTD), 19 January 1996 (1996-01-19) *

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2227815A2 (de) * 2007-06-15 2010-09-15 Cooper Technologies Company Abgeschirmte, magnetische miniaturkomponente
EP2227815A4 (de) * 2007-06-15 2013-05-01 Cooper Technologies Co Abgeschirmte, magnetische miniaturkomponente
DE202008004315U1 (de) * 2008-03-29 2009-08-06 Neosid Pemetzrieder Gmbh & Co. Kg Induktives Bauelement, insbesondere Antenne
WO2014116917A1 (en) * 2013-01-25 2014-07-31 Vishay Dale Electronics, Inc. A low profile high current composite transformer
CN104956453A (zh) * 2013-01-25 2015-09-30 韦沙戴尔电子公司 低轮廓高电流复合变压器
US10840005B2 (en) 2013-01-25 2020-11-17 Vishay Dale Electronics, Llc Low profile high current composite transformer
US10998124B2 (en) 2016-05-06 2021-05-04 Vishay Dale Electronics, Llc Nested flat wound coils forming windings for transformers and inductors
US10854367B2 (en) 2016-08-31 2020-12-01 Vishay Dale Electronics, Llc Inductor having high current coil with low direct current resistance
US11049638B2 (en) 2016-08-31 2021-06-29 Vishay Dale Electronics, Llc Inductor having high current coil with low direct current resistance
US11875926B2 (en) 2016-08-31 2024-01-16 Vishay Dale Electronics, Llc Inductor having high current coil with low direct current resistance
CN110914937A (zh) * 2017-05-29 2020-03-24 稀薄能源有限公司 薄变压器及其制造方法
US11948724B2 (en) 2021-06-18 2024-04-02 Vishay Dale Electronics, Llc Method for making a multi-thickness electro-magnetic device

Also Published As

Publication number Publication date
EP1091369A3 (de) 2002-04-17
JP2001143940A (ja) 2001-05-25

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