US3483497A - Pulse transformer - Google Patents

Pulse transformer Download PDF

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Publication number
US3483497A
US3483497A US697955A US3483497DA US3483497A US 3483497 A US3483497 A US 3483497A US 697955 A US697955 A US 697955A US 3483497D A US3483497D A US 3483497DA US 3483497 A US3483497 A US 3483497A
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US
United States
Prior art keywords
core
windings
die
grooves
plastic case
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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.)
Expired - Lifetime
Application number
US697955A
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English (en)
Inventor
Kendall Clark
Rudolph F Lia
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International Business Machines Corp
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International Business Machines Corp
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Publication of US3483497A publication Critical patent/US3483497A/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F19/00—Fixed transformers or mutual inductances of the signal type
    • H01F19/04—Transformers or mutual inductances suitable for handling frequencies considerably beyond the audio range
    • H01F19/08—Transformers having magnetic bias, e.g. for handling pulses
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core

Definitions

  • This invention relates to an improvement in the manufacture of ferromagnetic devices and, more particularly, to the fabrication of extremely small, annular bodies or cores having suitably dispossed windings and adapted for use in pulse transformers, memory elements, and the like.
  • the present invention is more particularly concerned with the fabrication of inductors and transformers comprising torodial cores, usually composed of ferrite material, surrounded by windings.
  • the invention is also concerned with a technique for so fabricating these devices that they are immediately ready for application, in the form of pulse transformers and the like, in electrical circuits. More specifically, they are made ready for installation in the form of so-called pluggable units.
  • the present invention envisions a technique for the fabrication of conductors and transformers comprising toroidal cores, whereby such devices are producible in great numbers by the integral die casting of the windings and connecing leads therefor.
  • the technique also includes the die casting of metal to surround the terminal pins. As as result, following the die casting operation the pluggable units are immediately ready for use in electrical circuits.
  • Another basic object is simultaneously to form the windings for the magnetic core and to place the core in a rigid package.
  • a further object is to have the package or housing itself constitute part of the means for forming the aforesaid windings and interconnections.
  • the present invention provides a winding construction and an associated encapsulation method which produces transformers, and like devices, disposed within a package, in the form of a plastic case or housing, such that the plastic case assists in the fabrication of the windings and assures that they are locked in place.
  • the windings, interconnections and terminal pins that are required for the transformers are all formed simultaneously by a die casting operation.
  • the die that is used is formed partly of steel or the like, while part of the die is constituted by portions of the plastic case.
  • the windings as they are fabricated to surround the core are in profile, i.e. they extend beyond the limits of the core body.
  • the core body including the insulation immediately surrounding the core has a certain fixed boundary defined by smooth or unbroken peripheral surfaces. The windings, as these are created, extend beyond the peripheral surfaces of the core body.
  • the required terminal pins are provided as die cast inserts.
  • the inserts are set into the die when the windings are to be formed and these inserts become locked into specially formed slots within the plastic case or housing.
  • the essence of the technique of the present invention may be considered as comprising the steps of simultaneously forming the windings in profile around an annular core body, forming these windings so that they are locked into a plastic case or housing which partly defines the die, whereby the entire core body or unit is firmly supported.
  • FIGURES lA-lF are perspective views illustrating a number of steps in the fabrication of a magnetic core pulse transformer or the like in accordance with the present invention.
  • FIGURE 2 is a sectional view taken through the die casting apparatus and showing the magnetic core unit which is about to be inserted for the die casting operation.
  • FIGURE 3 is another sectional view of the die casting apparatus showing such apparatus in the closed position, the magnetic core unit having been inserted therein.
  • FIGURE 4 is a bottom plan view of a typical magnetic core unit.
  • FIGURE 5 is a sectional view taken on the line 55 in FIG. 4.
  • FIGURE 6 is another sectional view taken on the line 66 in FIG. 5.
  • FIGURES 1A and 1B there is shown here a typical magnetic core unit which is to be fed to a die casting apparatus.
  • the magnetic core unit 120 consists of an annular ferrite core 100 completely surrounded by an adherent insulating covering 110. This insulating covering is necessary because the ferrite core material that is generally used is a conductor and it is therefore necessary to insulate the core from the windings that are to he placed around it.
  • a plastic housing or case 130 seen in FIG. 1C is provided for insertion with the core unit 120 at the die casting apparatus.
  • This plastic case 130 has been specially molded and has suitably disposed grooves 131 formed at spaced locations denoted 130a, 1301) and 1341c at the inner periphery of the case 130.
  • the case is also provided with a number of keystone shaped slots 133 at one end thereof.
  • the purpose of the grooves 130:: is to define, in the die casting operation, openings or recesses for reception of metal used to form parts of the windings for the core, while the purpose of the slots 133 is to receive the pins 132 and the metal which surrounds them, and thereby to lock the pins in place.
  • thermosetting plastic is the most preferred type of material for the case 130 which serves as the package for the magnetic core unit 120.
  • a thermosetting plastic material will not be deleteriously affected by the die casting operation that is to be performed with the present technique.
  • FIGURE 1D shows the assembly of the plastic case 130, the core unit 120 and the pins 132. As will be explained, these elements are integrally combined in the die casting operation.
  • the core unit is disposed within the plastic case 130 so that its outer peripheral surface abuts the inner peripheral sections of the case designated 130a, b and 0, whereby the series of spaced grooves 131 in these sections are immediately adjacent the outer periphery of the core unit 120.
  • the pins 132 are shown in position with their ends within the slots 133.
  • This assembly of FIGURE 1D represents the condition at which the die casting operation is about to be performed in the die casting apparatus of FIGURE 2.
  • each of the parts 140a and 140b contains a passageway 142a and 1421: respectively for receiving the metal from appropriate conduits, the metal being forced at the proper time into these passageways and then into the channels and recesses within the die.
  • the die parts 140a and 140b have their surfaces precisely formed to produce the desired winding configurations for the core unit 120. As will be understood a great variety of winding configurations can be obtained for the core unit 120.
  • the general objective in all instances is to define a helical winding or windings surrounding the core unit 120 and, at the same time, to provide the appropriate interconnection leads therefrom out to the ter- 4 minal pins 132 at the edge of the plastic case 130.
  • the grooves 131 in the plastic case 130 define certain of the axially extending outer peripheral portions while the die itself defines the remainder of these required portions.
  • the series of radially extending grooves 144a on the upper mold part 140a and the corresponding series of grooves 144b on the lower mold part 14017 serve to define the skewed portions of the windings, that is, those that extend along the radial plane surfaces of the core unit 120.
  • the grooves 144a and 14411 serve to define all of the upper and lower skewed portions 200x of the windings 200, as seen for example in FIGURE 1E.
  • the axially extending grooves 146a of the upper mold part meet and align with the corresponding grooves 14611 of the lower mold part 1401) and thereby serve to define the axially extending portions 200y of the windings 200 at the inner periphery of the core.
  • the series of grooves 148b in the lower mold part define the remaining outer peripheral, axially extending portions of the windings, that is, those not defined by the grooves 131.
  • windings 200 by the grooves which are adapted to receive the die cast metal, can be appreciated in greater detail by reference to the bottom plan view of FIGURE 4, wherein there will readily be seen the serial connection of the skewed portions 200x at the top and bottom radial faces of the core unit and the axially extending portions 200;) to form the helical windings shown.
  • the dotted lines for the portions 200x represent the upper radially extending portions of the several windings.
  • the interconnecting leads 220 are also formed by reason of the fact that suitable recesses or channels 210 are provided that connect with the winding pattern of grooves. These channels 210 connect respectively with the slots 133 provided in the plastic case at one end thereof.
  • the die is shown in the closed position in FIG. 3, the two heated sections or parts a and 14% having been clamped together. Also, another die part 140c is clamped together with the other parts of the die and serves to retain the pins 132.
  • the die is usually heated to a temperature of approximately 440 F., depending on the metal used.
  • a tin silver alloy was found to be the best composition in the fabricating of core windings. The percentage of silver was varied from about 5% upward to about 15%.
  • the terminal pins which are in the form of die cast inserts are made of silver plated copper.
  • the metal in the form of the aforenoted tin-silver composition is injected into the die by means of the movable conduits 410 and pressure is applied so as to result in forcing this tin-silver composition into the grooves, recesses and channels, as already described, which define the various windings and interconnecting leads.
  • the metal is forced into the grooves 131 at the inner periphery of the plastic case and into all the grooves in the die surfaces used for defining the windings for the core.
  • the metal flows through the channels 210 and into the slots 133 so as to surround the ends of the pins 132 which are held in these slots, the metal portion 142a is trimmed off.
  • FIG. 1E The resultant unit or assembly which is removed from the die casting apparatus is seen in FIG. 1E. It has all its essential elements connected by virtue of the die-casting operation such that the unit is now almost ready to be placed into service.
  • the core unit 120 is situated approximately midway of the depth dimension of the plastic case 130. The core unit is effectively locked in place in this location and is not easily moved about.
  • the stand-off projections 430 are provided at the pluggable end of the unit.
  • a second embodiment comprises a pulse transformer structure wherein the insulation 120 of core 100 is formed as a continuum of the case 130 by using the core 100 as an insert in the plastic mold during the molding of case 130, to the configuration of FIG. 1D.
  • An electrical component comprising an annular body, including an annular magnetic core surrounded by an adherent insulative coating, the periphery of said annular body being defined by completely smooth surfaces; a plastic case surrounding said annular body and having at its inner periphery a portion containing a plurality of spaced grooves, said portion contacting only the outer periphery of said annular body, said grooves containing metal so as to define in part at least one helical Winding around said annular body, and a separate encapsulant Within said casing and surrounding the remainder of said annular body.
  • An electrical component comprising an annular body, including an annular magnetic core surrounded by an adherent insulative coating, the periphery of said annular body being defined by completely smooth surfaces; at least one helical winding surrounding said annular body and being defined by metal conductors; a plastic case having spaced inner peripheral portions, each having axially extending grooves contacting only the outer periphery of said annular body, portions of the metal conductors being disposed in said grooves, and a separate encapsulant within said casing and surrounding the remainder of said annular body.
  • annular magnetic core is composed of ferrite material.
  • An electrical component as defined in claim 3 further comprising terminal pins for connecting said component to an external circuit, the terminal pins being disposed in slots to one end of said plastic case; and interconnecting leads extending from said winding so as to connect with the terminal pins in said slots.
  • a pulse transformer comprising an annular body, including an annular core completely surrounded by an inherent insulative coating, the periphery of said annular body being defined by completely smooth surfaces; a plastic case surrounding said annular body and having at its inner periphery a plurality of spaced grooves contacting only the outer periphery of said annular body, said grooves containing metal so as to define in part the helical windings for said annular body, the windings extending around said body to define a primary and a secondary for said transformer, and a separate encapsulant within said casing and surrounding the remainder of said annular body.
  • a pulse transformer comprising an annular body, including an annular magnetic core surrounded by an adherent insulative coating, the periphery of said annular body being defined by completely smooth surfaces; a plurality of helical windings surrounding said annular body and being defined by metal conductors; a plastic case having spaced inner peripheral portions, each having axially extending grooves contacting only the outer periphery of said annular body, portions of the metal conductors being disposed in said grooves, and a separate encapsulant within said casing and surrounding the remainder of said annular body.
  • a process of fabricating an annular magnetic core so as to define a winding therefor comprising the steps of disposing a plastic case in a die, said plastic case having a plurality of grooved portions at its inner periphery so as to provide recesses for receiving metal to define said winding,
  • said die further includes a plurality of channels for defining interconnecting leads from said windings to terminal pins.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Multimedia (AREA)
  • Insulating Of Coils (AREA)
  • Coils Or Transformers For Communication (AREA)
US697955A 1968-01-15 1968-01-15 Pulse transformer Expired - Lifetime US3483497A (en)

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US69795568A 1968-01-15 1968-01-15

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FR (1) FR96237E (id)
GB (1) GB1251122A (id)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4724603A (en) * 1985-08-13 1988-02-16 Commissariat A L'energie Atomique Process for producing a toroidal winding of small dimensions and optimum geometry
US6162311A (en) * 1998-10-29 2000-12-19 Mmg Of North America, Inc. Composite magnetic ceramic toroids
US6181130B1 (en) * 1997-07-25 2001-01-30 Tokin Corporation Magnetic sensor having excitation coil including thin-film linear conductor sections formed on bobbin with detection coil wound thereon
US20110205765A1 (en) * 2007-05-21 2011-08-25 Kabushiki Kaisha Toshiba Inductance element, method for manufacturing the same, and switching power supply using the same
CN102867620A (zh) * 2011-07-05 2013-01-09 台达电子工业股份有限公司 电感组件
US20130009738A1 (en) * 2011-07-05 2013-01-10 Chen Pi-Fan Inductor assembly
US8854167B2 (en) * 2012-02-22 2014-10-07 Mag. Layers Scientific-Technics Co., Ltd. Magnetic assembly
US20150287521A1 (en) * 2014-04-04 2015-10-08 Yazaki Corporation Coil fixation structure
US20160042854A1 (en) * 2014-08-08 2016-02-11 Hamilton Sundstrand Corporation Heat transfer in magnetic assemblies
US20170040106A1 (en) * 2014-04-16 2017-02-09 Premo S.L. Device for forming a toroidal coil and method for forming a toroidal coil
US10607760B2 (en) * 2015-07-17 2020-03-31 SUMIDA Components & Modules GmbH Coil body

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104766710B (zh) * 2015-04-22 2017-03-08 广东宽普科技股份有限公司 一种微型绕线电感及其制作方法

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2818514A (en) * 1952-10-02 1957-12-31 Bell Telephone Labor Inc Stressed ferrite cores
US2899631A (en) * 1959-08-11 Cushman
US2971138A (en) * 1959-05-18 1961-02-07 Rca Corp Circuit microelement
US3146332A (en) * 1961-12-06 1964-08-25 Yoder Co Welding transformer
US3155766A (en) * 1961-02-14 1964-11-03 Technitrol Inc Electrical component assemblage and casing therefor
US3246287A (en) * 1965-09-21 1966-04-12 Gen Dynamics Corp Piezoelectric transformer
US3251015A (en) * 1964-05-20 1966-05-10 Gen Electric Miniature magnetic core and component assemblies

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2899631A (en) * 1959-08-11 Cushman
US2818514A (en) * 1952-10-02 1957-12-31 Bell Telephone Labor Inc Stressed ferrite cores
US2971138A (en) * 1959-05-18 1961-02-07 Rca Corp Circuit microelement
US3155766A (en) * 1961-02-14 1964-11-03 Technitrol Inc Electrical component assemblage and casing therefor
US3146332A (en) * 1961-12-06 1964-08-25 Yoder Co Welding transformer
US3251015A (en) * 1964-05-20 1966-05-10 Gen Electric Miniature magnetic core and component assemblies
US3246287A (en) * 1965-09-21 1966-04-12 Gen Dynamics Corp Piezoelectric transformer

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4724603A (en) * 1985-08-13 1988-02-16 Commissariat A L'energie Atomique Process for producing a toroidal winding of small dimensions and optimum geometry
US6181130B1 (en) * 1997-07-25 2001-01-30 Tokin Corporation Magnetic sensor having excitation coil including thin-film linear conductor sections formed on bobbin with detection coil wound thereon
US6162311A (en) * 1998-10-29 2000-12-19 Mmg Of North America, Inc. Composite magnetic ceramic toroids
US20110205765A1 (en) * 2007-05-21 2011-08-25 Kabushiki Kaisha Toshiba Inductance element, method for manufacturing the same, and switching power supply using the same
US8125305B2 (en) * 2007-05-21 2012-02-28 Kabushiki Kaisha Toshiba Inductance element, method for manufacturing the same, and switching power supply using the same
TWI423279B (zh) * 2011-07-05 2014-01-11 Delta Electronics Inc 電感組件
US20130009738A1 (en) * 2011-07-05 2013-01-10 Chen Pi-Fan Inductor assembly
US8378770B2 (en) * 2011-07-05 2013-02-19 Delta Electronics, Inc. Inductor assembly
CN102867620A (zh) * 2011-07-05 2013-01-09 台达电子工业股份有限公司 电感组件
CN102867620B (zh) * 2011-07-05 2016-01-20 台达电子工业股份有限公司 电感组件
US8854167B2 (en) * 2012-02-22 2014-10-07 Mag. Layers Scientific-Technics Co., Ltd. Magnetic assembly
US20150287521A1 (en) * 2014-04-04 2015-10-08 Yazaki Corporation Coil fixation structure
US20170040106A1 (en) * 2014-04-16 2017-02-09 Premo S.L. Device for forming a toroidal coil and method for forming a toroidal coil
US10832866B2 (en) * 2014-04-16 2020-11-10 Premo, S.A. Device for forming a toroidal coil and method for forming a toroidal coil
US20160042854A1 (en) * 2014-08-08 2016-02-11 Hamilton Sundstrand Corporation Heat transfer in magnetic assemblies
US10607760B2 (en) * 2015-07-17 2020-03-31 SUMIDA Components & Modules GmbH Coil body

Also Published As

Publication number Publication date
FR96237E (id) 1972-05-19
GB1251122A (id) 1971-10-27

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