DE19725865A1 - Transformer winding structure e.g. for application in power pack - Google Patents

Abstract

The winding structure has two coils provided in parallel by folding a layered metal conductor (5a), which forms a closed loop with a rectangular shape in its unfolded condition. The layered metal conductor is folded over at its centre, so that the folded halves lie in spaced parallel planes either side of a lamination stack, with flattened terminals (5b-1,5b- 2) formed at the folded edge for connection to a printed circuit substrate.

Description

The invention relates to a technology for forming a transformer winding or winding, advantageous in the reduction of electricity or energy losses and heat radiation in the transformer used in a current or Power supply or in a power supply and the like, formed from thin Parts, including flat windings or turns.

The most critical point of view when making an outer shape of a thin one Transformer is the question of how to make a thin winding or turn of the Transformers forms. So far, transformers with thin outer Forms formed by forming conductive patterns with inductance on insulating layers or sheets or substrates, laminating this isolie layers or substrates, and subsequently forming a transformer windings or turns. The insulating layers or substrates which Have conductors or line or conductive patterns with inductance, formed on their surface or surface, layer coils or printing or printed te coils (hereinafter referred to as layer coils).

Fig. 1 is a perspective view showing an example of a conventional transformer with a thin outer shape using this film coil as a winding.

The transformer shown in Fig. 1 has a primary winding and a secondary winding, which are formed by a layer coil or winding or winding laminate 1 a, formed by laminated layer coils, equivalent to a winding or winding, and has such a structure that the layer coil laminate 1 a is installed in a core 2 , connections 4 a and 4 d for both being inserted into through holes 3 a to 3 d of the layer pull laminate 1 a in order to be soldered.

In the present case, the through holes 3 a to 3 d of the layered pull laminate 1 a are formed from through holes of respective layer coils, which are electrically connected or connected with or insulated from line or conductor patterns on the layer coils. This results in line patterns on the respective layer coils and line patterns formed on a circuit substrate, electrically connected or switched via the connections 4 a to 4 d, and the through holes 3 a to 3 d, both of which are soldered to one another.

The transformer shown in Fig. 1 uses the terminals 4 a to 4 d for electrically connecting the line pattern to the layer coil as a winding with the circuit pattern on the circuit substrate. It is therefore necessary to solder the through holes 3 a to 3 d to the connections 4 a to 4 d.

In the present case, when there is a strong current from the secondary winding of the If the transformer is delivered to a load, a current or power is generated or energy loss at the soldering sections between the line patterns of the Layer coils and the connections, due to the occurring in them Current flow. Usually the solder material is an alloy, significantly formed made of tin, tin having a resistance which is about 8 times that electrical resistance of copper, which is used for the Line patterns on the layer coils and connections. This may result Loss of current, power or energy, occurring at the soldering sections, become remarkably large.

In addition, heat generated in the line patterns on the layer coils is not only conducted along the surfaces of the layer coil laminate 1 a, but is also conducted to the connections and circuit patterns of the circuit substrate. Thus, the heat is emitted from each surface of the layered pull laminate 1 a, the connections 4 a to 4 d and a circuit pattern. However, the thermal conductivity of the solder is lower than that of copper, and heat is generated at the solder portions due to current or power loss, and thus a thermal gradient between the wiring patterns on the layer coils and metal terminals becomes large. As a result, the thermal conductivity may deteriorate, and thus radiation or radiation may not be efficient.

Thus, the objects of the present invention are as follows.

The first task is to reduce electricity, power or energy losses reduce which are caused by soldering sections between lines cut the winding and connectors, by improving the structure of one Transformer winding.

The second task is to efficiently run the winding to conduct or dissipate generated heat or heat and to radiate or to radiate or radiate by improving the structure of the transformer winding.

The present invention is characterized in terms of the winding structure that a layer metal conductor, which forms a closed loop, if unfolded flat on the central section of the long side, folded from it, whereby the folded portions of the folded metal conductor are used as connectors be, wherein two coils are formed parallel to each other and the Wick used for a transformer or forms.

The following is a description of a specific embodiment of the Invention regarding the manufacturing process steps specified.

The surfaces of a layer metal conductor, which is a square frame-like closed loop forms, when unfolded flat, with Exception of the middle section of the long sides isolated. This metal ladder  is folded at the middle sections, which are not insulated. Furthermore predetermined positions are bent or flexed, the positions Parts of the long sides of the metal conductor or metallic conductor are which between the folded sections and a transverse side, so that Areas or surfaces of the two transverse or transverse sides facing each other are arranged lying to each other and parallel to each other. Below will be the folded, bent sections used as connectors, two Single revolution or single coils are formed parallel to each other.

The winding is used as a transformer winding for large current capacitors act, the winding has two coils and connection sections, which be obtained by this method and are made in one piece.

The transformer is arranged so that the winding is sandwich-like Can have structure with good coupling between windings Insert other windings between the two single coils of the winding.

As described above, the invention is characterized in the winding structure characterized in that two single coils (coil parts) are formed by one Layer metal conductor, which forms a closed loop when flat tet, which is folded, wherein a winding is formed by connecting parts and coil parts, which are in one piece or in one body or in one piece are formed.

Due to this structure, it becomes unnecessary to conductors and connections of a wick soldering, and thus the formation of electricity or energy or Performance losses and increases with regard to a thermal gradient at solder sections that are problematic with the conventional structure are avoided are matical. Furthermore, the winding structure according to the invention is wide ren advantage that a sandwich-like structure to increase the coupling between windings can be easily reached because the winding is two Has coil parts in one body or in one piece. It can also be more direct Components are connected or directly connected to one another by  partial widening or widening of the conductor width of the metal conductor. In In this case, the winding structure has the further advantage that it does not only the arrangement density of the components in a device is increased, but rather that the loss of electricity or power or energy is lowered, which is caused by the soldering sections or the soldering sections of the other components.

Fig. 1 is a perspective view showing an outer shape of a conventional transformer.

Fig. 2 is a perspective view showing an outer shape of a first embodiment of a transformer in which the winding structure according to the invention is provided.

Fig. 3 is a cross-sectional view showing the first embodiment of a transformer, wherein said winding structure according to the invention is provided and attached or applied.

Fig. 4 is a comparative drawing showing the unfolded state of a metal conductor, before the formation and the formed state of the winding, as the basis of the winding structure according to the invention.

Fig. 5 is a perspective view of an outer shape of a second embodiment of a transformer in which the winding structure of the invention is provided.

FIG. 6 is an equivalent circuit of the second embodiment of a transformer, in which the winding structure according to the invention is provided or attached.

Fig. 7 is an unfolded view of a metal conductor before forming, used as a winding for the second embodiment of a transformer.

Fig. 8 shows a third embodiment of a transformer in wel chem the winding structure of the invention is provided.

Fig. 9 is an equivalent circuit to the third embodiment of a transformer in which the winding structure according to the invention is provided.

Fig. 2 and 3 show a first embodiment of a transformer in which the winding structure of the invention is provided and used or applied or arranged, wherein the winding structure tion or genera generation or formation of current or power or Energy loss is reduced and it is possible to effectively radiate or dissipate heat generated or generated in the windings.

The transformer shown in a perspective view of FIG. 2 has a structure in which the primary winding is formed from a layered pull laminate 1 b, the secondary winding is formed from a winding 5 , and wherein the layered pull laminate 1 b and the winding 5 in one Core 2 are installed. In addition, the structure has connections 4 a and 4 b, leads into through holes 3 a and 3 b of the layered pull laminate 1 b, both being soldered to one another as is conventional.

In the present case, the winding 5 is formed as shown in FIG. 4.

First, a layer metal conductor 5 a is provided, the flat shape of which forms a square frame-like closed loop in the unfolded or unfolded state before molding and is covered and insulated, with the exception of middle sections of the long sides, with insulation or isolate the material 6 .

The square frame-like metal conductor 5 a is folded at predetermined positions (a) of the middle section, which is not insulated. The metal conductor 5 a is then bent or bent at the predetermined positions (b) and (c), in this case on the long sides, in such a way that two transverse or transverse sides of the metal conductor 5 a are arranged opposite one another and in parallel. After these process steps, the folded sections 5 b-1 and 5 b-2 are formed as connections of the winding, the isolating sections forming coil parts 5 c-1 and 5 c-2 as coil conductors of the winding.

The winding 5 obtained as described above, as shown in a cross-sectional view of FIG. 3, is installed in the core 2 , specifically in the state of the insertion or insertion of the layered pull laminate 1 b between the coil parts 5 c-1 and 5 c-2. In such a transformer, in which the winding structure according to the invention is provided or used or is applied or arranged, soldering or soldering is not necessary, due to the fact that the winding 5 as a secondary winding integrally the coil parts 5 c-1 and 5 c -2, and the connecting parts 5 b-1 and 5 b-2. Thus, the formation or generation or generation of energy loss and increase in the thermal gradient can be avoided, which is problematic with conventional structures.

Furthermore, it is known that the sandwich-like structure in which a primary winding and a secondary winding are alternately arranged, and in which one winding is arranged between another winding, is an effective means of increasing the coupling between the windings. The winding structure according to the invention has the further advantage that the sandwich-like structure can be easily achieved, due to the fact that the winding 5 has two coil parts 5 c-1 and 5 c-2 in one piece or in one body.

It may also be necessary to provide a plurality of output channels on the secondary side of a transformer according to power supply specifications. A second embodiment is shown in FIG. 5, wherein in this embodiment the winding structure according to the invention is applied to such a case.

In Fig. 5, the embodiment is characterized in the structure of a winding 7 , which forms a single-body type or an integral type of secondary winding for two transformers T2 and T3. An equivalent circuit of an electrical circuit is shown in Fig. 6, wherein the equivalent circuit includes the transformers T2 and T3, which include the winding 7 .

Since the connection parts 7 b-2 act similarly to the winding 7 or function with respect to an interposed or interposed tab of a winding, it becomes possible to have two output or output channels between the connection parts 7 b-1 and 7 b-2 and between the Provide connecting parts 7 b-2 and 7 b-3.

The winding 7 shown in Fig. 5 is formed by folding the metal conductor 7 a, which forms a dual or double closed loop, as shown in Fig. 7, at predetermined positions (a) and by further bending or Bend it at positions (b) and (c). Accordingly, a first closed loop 7 d-1 becomes the secondary winding of transformer T2, and a second closed loop 7 d-2 becomes the secondary winding of transformer T3.

Furthermore, if additional output channels are required, this can be done can be achieved by forming secondary windings with metal conductors, which form closed loops, their number of the required number of off correspondence channels, with a variety of transformers provided is.

When miniaturizing an entire power supply device or a ge the entire power supply will increase the arrangement density of the components important point of view. When components are directly connected without a circuit pattern on a circuit substrate  to pass through, the distances between the components are shortened, and thus the arrangement density can be increased.

In the winding structure according to the invention, a layer metal conductor is used, and thus a third embodiment of the invention, shown in FIG. 8, is designed on the basis of the idea that parts of a metal conductor can be used for the electrical connection or for the electrical connection between components instead of the circuit pattern.

In FIG. 8, a winding 8 is formed by using a metal conductor having a broadened line width close to a folded position, and thus has a terminal part 8 b-1 in a large area. Thus, the connection part 8 b-1 has a shape which can simply be used directly for connecting or connecting the winding 8 of a transformer T4 with a diode D.

Such a winding structure is effective, not just to increase the arrangement density of the components, but also reduces electricity or energy or loss of performance due to soldered parts of the entire device.

Further, FIG. 9 is an equivalent circuit diagram of a gezeig th in Fig. 8 electrical circuit in which the transformer T4 and the diode D are directly connected or connected.

In the respective embodiments of the invention described above, the primary winding is the layered pull laminate 1 b, and the secondary windings are the windings 5 , 7 and 8 according to the invention, which are formed by folding metal conductors. However, the present invention is not limited to this, and the present invention can be applied to the primary winding, a third or further winding.

In addition, another winding, inserted between windings with the structure according to the invention, by winding or winding a conductor be seen instead of a layer coil.  

Furthermore, if a layer type of insulation material 6 , as shown in FIG. 4, is not used, coating of wax can be used, for example, to insulate a metal conductor.

If adequate isolation and security can be obtained through a Device housing and the like, isolation of the metal conductor can give otherwise stay away.

Claims (5)

1. A transformer winding structure comprising: two coils, in parallel provided by folding a layer metal conductor, which is a closed sene loop, when unfolded flat, forms on middle sections of the Layer metal conductor; and connectors formed by bending folded Portions of the layer metal conductor to a circuit substrate. 2. A transformer winding structure comprising: terminals formed from folded sections of a layer metal conductor, formed by folding the Layer metal conductor, which forms a closed loop, if unfolded flat, on middle sections of the layer metal conductor, and by bending long sides of the layer metal conductor, so that two cross sides of the layer metal conductor opposite to each other and parallel can be arranged; and two parallel coils. 3. A transformer winding structure comprising: at least one winding under a variety of transformer windings, with connections, formed from folded sections of a layer metal conductor by folding the layer metal conductor, which is a closed loop forms when unfolded flat, at central portions of the layer metalleiters, and by bending long sides of the layer metal conductor, so that two transverse sides of the layer metal conductor are opposite one another and can be arranged in parallel; two coils, which are parallel run; and another winding, inserted between the two parallel coils. 4. transformer winding structure according to any one of claims 1 to 3, which enables a connection to be electrically connected directly  with another electrical part by enlarging an area or a surface of the connection of a winding, formed by a folded section, by widening the wire width near the folded position of the layer metal conductor. 5. transformer winding structure according to any one of claims 1 to 3, which the layer metal conductor has planes similar to square frames, if the layer metal conductor is folded out before forming.