EP3291253A1 - A toroidal magnetic core with windings - Google Patents
A toroidal magnetic core with windings Download PDFInfo
- Publication number
- EP3291253A1 EP3291253A1 EP16460063.7A EP16460063A EP3291253A1 EP 3291253 A1 EP3291253 A1 EP 3291253A1 EP 16460063 A EP16460063 A EP 16460063A EP 3291253 A1 EP3291253 A1 EP 3291253A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- windings
- ring
- layer
- etching
- winding
- 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- Withdrawn
Links
- 238000004804 winding Methods 0.000 title claims abstract description 84
- 230000005291 magnetic effect Effects 0.000 title claims abstract description 12
- 238000005530 etching Methods 0.000 claims abstract description 25
- 238000000034 method Methods 0.000 claims abstract description 21
- 239000011248 coating agent Substances 0.000 claims abstract description 16
- 238000000576 coating method Methods 0.000 claims abstract description 16
- 238000004519 manufacturing process Methods 0.000 claims abstract description 12
- 239000002184 metal Substances 0.000 claims abstract description 7
- 229910052751 metal Inorganic materials 0.000 claims abstract description 7
- 239000007769 metal material Substances 0.000 claims abstract description 3
- 239000003822 epoxy resin Substances 0.000 claims description 4
- 239000003302 ferromagnetic material Substances 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 239000004020 conductor Substances 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 230000005684 electric field Effects 0.000 abstract description 2
- 238000009413 insulation Methods 0.000 description 8
- 239000004033 plastic Substances 0.000 description 5
- 229920003023 plastic Polymers 0.000 description 5
- 239000003989 dielectric material Substances 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 230000007812 deficiency Effects 0.000 description 3
- 238000004382 potting Methods 0.000 description 3
- 230000015556 catabolic process Effects 0.000 description 2
- 230000001427 coherent effect Effects 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 229920006334 epoxy coating Polymers 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000002609 medium Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/0006—Printed inductances
- H01F17/0033—Printed inductances with the coil helically wound around a magnetic core
-
- 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
- H01F17/06—Fixed inductances of the signal type with magnetic core with core substantially closed in itself, e.g. toroid
- H01F17/062—Toroidal core with turns of coil around it
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus 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
- H01F41/02—Apparatus 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 for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus 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 for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/041—Printed circuit coils
- H01F41/046—Printed circuit coils structurally combined with ferromagnetic material
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Coils Or Transformers For Communication (AREA)
Abstract
The subject of the invention is a toroidal magnetic core with windings and a method of manufacturing such core. The invention has an application as a transformer or an inductor in the electrical field, especially for high voltage application. A toroidal magnetic core with windings characterised in that it comprises a metal ring (1) which is covered with insulating coating (2) on which a conductive layer (3) of a metal material is disposed around the core (1) for making at least one conductive winding (5) helically disposed around the core (1) on the insulating coating (2). The windings (5) have singular turns (3') and between each turn (3') of the winding (5) a helical grove (4) is placed for insulating the neighbouring turns (3') one from of the otlier and the groves (4) have a depth equal to a thickness of a conductive layer (3) from which the winding (5) is made during a process of etching the layer (3).
Description
- The subject of the invention is a toroidal magnetic core with windings and a method of manufacturing such core. The invention has an application as a transformer or an inductor in the electrical field, especially for high voltage application.
- Toroidal transformers or inductors are becoming ever more popular. Their windings are usually done using toroidal winding machines and magnet wire. There are however certain applications where winding on a toroidal core becomes a bit cumbersome. Traditional winding may cause some issues related to the insulation quality when applied to the high insulation voltage transformer, as the geometry of the winding influences the field distribution, moreover the repeatability of the geometry of winding is not that easy to keep with the normal winding method. The traditional toroidal winding when applied to the high insulation voltage transformer may cause some tissues when trying to achieve high voltage insulation between the windings which are relatively close to each other. The issues are related mostly to uneven field distribution caused by the geometry of the winding as well as difficulty to properly fill the space between the windings with the dielectric material. High insulation voltage between two separate electrical networks which are residing in close proximity to each other is achievable by the use of dielectric material with high dielectric strength. To assure the long term reliability of such insulation the dielectric material between the two networks must be free of any voids which may cause partial discharges leading to the degradation of the insulating barrier. As an insulating medium, epoxy, polyurethane or silicone potting is used in the electronic equipment whose electronic networks must be insulated from each other. The insulation degradation is related mostly to uneven field distribution caused by the geometry of the winding as well as difficulty to properly fill the space between the windings with the dielectric material. Often the potting applied to the traditionally wound transformer does not penetrate the-winding living small air pockets which become a source of the partial discharges. In order to omit deficiencies of the prior art there is a need for design of an improved magnetic core with windings.
- US patent application
US 2005/0156703 describes a toroidal winding whose aim is to filter unwanted noise from electrical connectors and devices. Here the toroid comprises a metal ring surrounded by a plate-able and non-plate-able plastic cast, and a conductive layer deposited onto the plate-able cast. The toroid is manufactured by first molding the non-plate-able plastic, having helically pattered grooves, around the metal ring. The plate-able plastic is then molded into the grooves of the non-plate-able plastic. A conductive plating is then electrodeposited onto the plate-able plastic to form a helically patterned winding around the metal ring. The method according to this solution allows for manufacturing a toroid in automatic process easier than in comparison with the traditional winding conductors. This solution although feasible, seems quite expensive and difficult to manufacture, moreover it does not address the issues mentioned above. Even though the geometry of the windings is repeatable here, hence the manufacturing issues related to geometry field distortion are resolved, the method calls for casts associated with windings and casts are known for having air voids inside. It also seems that the spacing between the turns are relatively large due to the necessity of having two kinds of casts. This implies field distortion. - The essence of a toroidal magnetic core with windings according to the invention is that the core comprises a metal ring which is covered with insulating coating, on which a conductive layer of a metal material is disposed around the core. The conductive layer is disposed for making at least one conductive winding helically placed around the core on the insulating coating. The windings have singular turns and between each turn a helical grove is placed for insulating the neighbouring turns one from of the other. The groves have a depth equal to a thickness of a conductive layer from which the winding is made during a process of etching the layer.
Preferably the widths of each turn are bigger than the width of each grove.
Preferably the conductive winding has their ends adapted as terminals for electrical connection with any electrical conductors.
Preferably the insulating coating is made from an epoxy resin.
Preferably the conductive layer is made of copper. - An essence of the method of manufacturing a toroidal magnetic core with windings where the windings are helically disposed around a toroidal ring depends on the following steps:
- manufacturing the toroidal ring from the ferromagnetic material,
- covering a whole surface of the ring with an insulating coating,
- disposing on the entire surface of the coating a conductive layer,
- choosing at least one part of the ring with the conductive layer for etching in the layer some grooves helically disposed on the ring,
- etching grooves in the layer by one of the known method of etching until receiving a clear surface of insulating layer of the ring,
- leaving the unetched parts of conductive layer as electrical conductive winding disposed between the helical grooves and having a singular turns helically disposed around the chosen part of the ring.
- Preferably the method comprises an additional step of adapting ends of the conductive windings as electrical terminals of the windings.
Preferably the step of etching grooves in the conductive layer is carried out on two parts of the ring forming two windings disposed an opposite each other.
Preferably the step of etching groves in the conductive layer is carried out by classical etching like for etching the printed circuit boards or by laser burning.
Preferably the conductive layer is made of cooper.
Preferably the insulating layer made of epoxy resin.
A toroidal transformer characterized in that it has a ring with windings according to claims 1-5.
A toroidal inductor characterized in that it has a ring with windings according to claims 1-5. - The main advantage of the invention is to provide a transformer core for high voltage application which has a simple construction and forms more reliable unit being a transformer or inductor. The core has the windings placed very tight, which is important for high voltage application as this allows linearization of the field between the low and the high voltage windings, reducing the stress on the insulating material. The winding together with the core create relatively flat equipotential surface, hence the deficiency of the traditional winding where the geometry can vary, are eliminated. The new process of manufacturing the core according to the invention improves the geometrical repeatability of windings allowing to create uniform flat equipotential surface of the winding, which will promote a better field distribution between the primary and the secondary windings. Due to this fact the assembly of the transformer or inductor allows to eliminate issues related to potting, helping to achieve good coherent layer of the insulation between the windings.
- A toroidal core according to the invention is presented in the drawing where:
Fig.1 shows a toroidal magnetic core with one singular winding on the core in an axonometric view, andFig.2 shows the toroidal magnetic core with the singular winding in the cross-section of the core. - A toroidal magnetic core comprises a
ring 1 covered by a layer of aninsulating coating 2. Thering 1 is made of a ferromagnetic material. The insulating coating is an epoxy coating or other type of insulating material. The thickness of theinsulating layer 2 should be selected according to the technical requirement of a transformer or inductor for which the core is designed. On theinsulating layer 2, a plate-ableconductive layer 3 is disposed which is indicated in the drawing by a dashed lines. The plate-able layer 3 is made of conductive metal, preferably copper. The plate-able layer 3 becomes a material for etching in it or laser burning thegrooves 4 which are helically disposed on at least one part of thering 1 coated with theinsulating layer 2. The groves have a thickness equal of the thickness of the plate-ableconductive layer 3. The unetched surfaces of thelayer 3 create a helicalelectrical winding 5 of a toroidal core. The widths of the unetched surfaces of thelayers 3 forming turns 3' preferably are bigger than the width of thegroves 4 what has a practical meaning in creating verytight winding 5. The winding 5 are ended byterminals 5a to which supply leads are attached by soldering or welding. The leads are not presented on the drawing. The winding 5 are disposed on the core in as many places as practical however in the drawing presents only one singular windings. - The method of manufacturing the core according to the invention comprises the following steps:
- manufacturing the
toroidal ring 1 from the ferromagnetic material, - covering the whole surface of the
ring 1 with an insulatingcoating 2, - disposing on the entire surface of ring coating 2 a
conductive layer 3, - choosing a part of the
ring 1 with the conductive 3 layer for etching in thelayer 3 somegroves 4 helically disposed on thering 1, -
etching grooves 4 in thelayer 3 by one of the known method of etching until receiving the clear surface of insulatinglayer 2 of thering 1, - leaving the unetched parts of
layer 3 as electrical conductive winding 5 disposed between thehelical groves 4 and having a singular turns 3' helically disposed around the chosen part of thering 1. - Additionally the method comprises the step of adapting the ends of the
conductive windings 5 forterminals 5a of the windings. - After the process of etching grooves the in the
conductive layer 3, creating a helically disposedgrooves 4 down to the insulatinglayer 2, the remaining part of theconductive layer 3 creates a winding 5 of a transformer or an inductor. The conductive surface of the winding 5 could be etched in many different ways, depending on the required properties of transformer or the inductor. One of the options is to leave a conductive layer covering almost all toroidal ring and creating etched traces. This is practical for some specific application create an equipotential surface. Thewindings 5 are etched by the process similar to the one used for etching the printed circuit boards. Alternatively the windings could be etched by laser burning the narrow gaps in theconductive layer 3. This process allows to create very tight winding 5. At the same time the winding together with the core create relatively flat "equipotential" surface, hence the deficiencies of the traditional winding should be eliminated. This allows for equalization of the field between the low and high voltage windings, hence improve partial discharge situation. The winding would create one coherent block together with the core, which would create a uniform surface The preparation of theterminals 5a of the winding 5 is performed by the know way for making electrical connection by welding or soldering. The step of etchinggroves 4 in theconductive layer 3 is carried out on at least one part of thering 1 but it is provided in many part of thering 1 what is not presented in the drawing. Preferably the step of etchinggroves 4 in theconductive layer 3 is carried out in two parts of the ring forming twowindings 5 disposed an opposite each other.
Claims (13)
- A toroidal magnetic core with windings characterised in that it comprises a metal ring (1) which is covered with insulating coating (2) on which a conductive layer (3) of a metal material is disposed around the core (1) for making at least one conductive winding (5) helically disposed around the core (1) on the insulating coating (2); the windings (5) have singular turns (3') and between each turn (3') of the winding (5) a helical grove (4) is placed for insulating the neighbouring turns (3') one from of the other and the groves (4) have a depth equal to a thickness of a conductive layer (3) from which the winding (5) is made during a process of etching the layer (3).
- A core according to claim 1, characterised in that the widths of the turn (3') are bigger than the width of the groove (4).
- A core according to claims 1-2, characterised in that the conductive winding (5) has their ends (5a) adapted as terminals for electrical connection with any electrical conductors.
- A core according to claim 1, characterised in that the insulating coating (2) is made from an epoxy resin.
- A core according to claim 1, characterised in that the conductive layer (3) is made of copper.
- A method of manufacturing a toroidal magnetic core with windings (5) where the windings are helically disposed around a toroidal ring (1) comprising the steps of:- manufacturing the toroidal ring (1) from the ferromagnetic material,- covering a whole surface of the ring (1) with an insulating coating (2),- disposing on the entire surface of the coating (2) a conductive layer (3),- choosing at least one part of the ring (1) with the conductive layer (3) for etching in the layer (3) some groves (4) helically disposed on the ring (1),- etching groves (4) in the layer (3) by one of the known method of etching until receiving a clear surface of insulating layer (2) of the ring (1),- leaving the unetched parts of layer (3) as electrical conductive winding (5) disposed between the helical groves (4) and having a singular turns (3') helically disposed around the chosen part of the ring (1).
- A method according to claim 6, characterized in that it comprising additional step of adapting ends of the conductive windings (5) for electrical terminals (5a) of the windings.
- A method according to claim 6, characterized in that the step of etching groves (4) in the layer (3) is carried out on two parts of the ring (1) forming two windings (5) disposed an opposite each other.
- A method according to claim 6, characterized in that the step of etching groves (4) in the layer (3) is carried out by classical etching like for etching the printed circuit boards or by lase burning.
- A method according to claim 6, characterized in that the conductive platable layer (3) is carried out from cooper.
- A method according to claim 6, characterized in that the insulating layer (2) is carried out from epoxy resin.
- A toroidal transformer characterized in that it has a ring (1) with windings (5) according to claims 1-5.
- A toroidal inductor characterized in that it has a ring (1) with windings (5) according to claims 1-5.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP16460063.7A EP3291253A1 (en) | 2016-09-02 | 2016-09-02 | A toroidal magnetic core with windings |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP16460063.7A EP3291253A1 (en) | 2016-09-02 | 2016-09-02 | A toroidal magnetic core with windings |
Publications (1)
Publication Number | Publication Date |
---|---|
EP3291253A1 true EP3291253A1 (en) | 2018-03-07 |
Family
ID=56979499
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP16460063.7A Withdrawn EP3291253A1 (en) | 2016-09-02 | 2016-09-02 | A toroidal magnetic core with windings |
Country Status (1)
Country | Link |
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EP (1) | EP3291253A1 (en) |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2330300A1 (en) * | 1973-06-14 | 1975-01-02 | Siemens Ag | ELECTRICAL COMPONENT |
DE2437116A1 (en) * | 1974-08-01 | 1976-02-12 | Siemens Ag | Inductor produced by using laser beam to cut helical winding - is made using non-magnetic metal coating on rotated toroidal core |
GB1502490A (en) * | 1974-05-14 | 1978-03-01 | Seikosha Kk | Coil windings and a method of making the same |
CN1065749A (en) * | 1992-02-26 | 1992-10-28 | 西安交通大学 | Method for making toroidal coil by space projection image formation mask-free photoetch |
US20050156703A1 (en) | 2004-01-20 | 2005-07-21 | Mark Twaalfhoven | Magnetic toroid connector |
CN102254677A (en) * | 2010-05-19 | 2011-11-23 | 长盛科技股份有限公司 | Closed loop iron core coiling method and structure |
US20140159853A1 (en) * | 2012-12-07 | 2014-06-12 | Delta Electronics (Chen Zhou) Co., Ltd | Magnetic passive component and method for manufacturing the same |
-
2016
- 2016-09-02 EP EP16460063.7A patent/EP3291253A1/en not_active Withdrawn
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2330300A1 (en) * | 1973-06-14 | 1975-01-02 | Siemens Ag | ELECTRICAL COMPONENT |
GB1502490A (en) * | 1974-05-14 | 1978-03-01 | Seikosha Kk | Coil windings and a method of making the same |
DE2437116A1 (en) * | 1974-08-01 | 1976-02-12 | Siemens Ag | Inductor produced by using laser beam to cut helical winding - is made using non-magnetic metal coating on rotated toroidal core |
CN1065749A (en) * | 1992-02-26 | 1992-10-28 | 西安交通大学 | Method for making toroidal coil by space projection image formation mask-free photoetch |
US20050156703A1 (en) | 2004-01-20 | 2005-07-21 | Mark Twaalfhoven | Magnetic toroid connector |
CN102254677A (en) * | 2010-05-19 | 2011-11-23 | 长盛科技股份有限公司 | Closed loop iron core coiling method and structure |
US20140159853A1 (en) * | 2012-12-07 | 2014-06-12 | Delta Electronics (Chen Zhou) Co., Ltd | Magnetic passive component and method for manufacturing the same |
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