Planar transformer having integrated ring core

Abstract

A planar, in particular intrinsically safe transformer, having: a sandwich-type layer structure having a plurality of layers extending horizontally and arranged vertically on top of one another, including a first and a second conductive layer and at least one insulating inner layer disposed between the two conductive layers, a plurality of electrical circuits, wherein a first electrical circuit and at least a second electrical circuit are galvanically isolated from each other; and at least one ring-type magnetic core having a hole, which acts at least on the first electrical circuit and the second electrical circuit. The core is arranged within the at least one insulating inner layer, a conductor of the first electrical circuit and a conductor of the second electrical circuit each have a winding with at least one winding turn, and the at least one winding turn of the first electrical circuit and the at least one winding turn of the second electrical circuit each run along the first conductive layer and along the second conductive layer and through the at least one insulating inner layer and through the hole of the core.

Claims

1. A planar, intrinsically safe transformer having a vertical dimension and a horizontal dimension, comprising: a sandwich-type layer structure including a plurality of layers extending horizontally and arranged vertically on top of one another, comprising a first and a second conductive layer and at least one insulating inner layer disposed between the two conductive layers; a plurality of electrical circuits, wherein a first electrical circuit and at least a second electrical circuit are galvanically isolated from each other; and at least one ring-type magnetic core having a hole, which acts at least on the first electrical circuit and on the second electrical circuit, wherein the core is arranged within the at least one insulating inner layer; a conductor of the first electrical circuit and a conductor of the second electrical circuit each have a winding with at least one winding turn, wherein the at least one winding turn of the first electrical circuit and the at least one winding turn of the second electrical circuit each extends along the first conductive layer and along the second conductive layer and through the at least one insulating inner layer and through the hole of the core; and an insulation provided around the magnetic core enclosing the magnetic core in all spatial directions, wherein the insulation is formed by the insulating inner layer and has a thickness, which guarantees a second isolation distance between the core and all other electrically conductive structures of the electric circuits and which is equal to or greater than half a first minimum isolation distance, wherein the first minimum isolation distance is defined as a minimum separation distance between the first electrical circuit and the second electrical circuit.

2. The transformer as claimed in claim 1, wherein: at least one first conductive track for the first electrical circuit and at least one second conductive track for the second electrical circuit are defined by each of the first conductive layer and the second conductive layer; and the at least one winding turn of the first electrical circuit comprises the first conductive track of the first conductive layer and the first conductive track of the second conductive layer, which are interconnected at one of their free end portions through a conductive via extending through the at least one insulating inner layer; and the at least one winding turn of the second electrical circuit comprises the second conductive track of the first conductive layer and the second conductive track of the second conductive layer, which are interconnected at one of their free end portions through a conductive via extending through the at least one insulating inner layer.

3. The transformer as claimed in claim 1, wherein at least one of the first electrical circuit and the second electrical circuit comprises a plurality of winding turns, and wherein the plurality of winding turns of an electrical circuit are interconnected such that a conductive track of the one winding turn is connected to a conductive track of the further winding turn at one of their free conductive track end portions through a conductive via extending through the at least one insulating inner layer.

4. The transformer as claimed in claim 3, wherein the first electrical circuit and the at least second electrical circuit have a first isolation distance to each other, and wherein the first isolation distance between the electrical circuits at least corresponds to the first minimum isolation distance at any geometric location of the transformer.

5. The transformer as claimed in claim 1, wherein at least one of the first conductive layer and the second conductive layer is an outer layer of the sandwich-type layer structure; and wherein each conductor of the first electrical circuit extending along an outer conductive layer has a third isolation distance to each conductor of the at least second electrical circuit extending along the same outer conductive layer; and wherein the third isolation distance between the electrical circuits corresponds at least to a second minimum isolation distance at any geometric location of the respective outer conductive layer of the transformer.

6. The transformer as claimed in claim 1, wherein the sandwich-type layer structure comprises at least one insulating outer layer; and wherein at least one of the first conductive layer and the second conductive layer are disposed between an insulating inner layer and an insulating outer layer.

7. The transformer as claimed in claim 6, further comprising a conductive layer disposed between two insulating layers so that the conductive layer comprises an inner conductive layer of the sandwich-type layer structure, each conductor of the first electrical circuit extending along an inner conductive layer has a first isolation distance to each conductor of the at least second electrical circuit extending along the same inner conductive layer; and wherein the first isolation distance between the electrical circuits corresponds at least to the first minimum isolation distance at any geometric location of the respective inner conductive layer of the transformer.

8. The transformer as claimed in claim 1, wherein the at least one insulating inner layer has a ring-type recess in which the ring-type magnetic core is embedded.

9. The transformer as claimed in claim 1, wherein at least two insulating inner layers are arranged on top of one another and joined to each other, in particular pressed together.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a table with clearances and creepage distances and separation distances with respect to specific levels of protection, the values contained therein corresponding to Table 5 of the standard EN 60079-11 as applicable at the priority date of the present application;

(2) FIG. 2 is a schematic perspective view of a transformer comprising two electrical circuits according to a first exemplary embodiment of the invention;

(3) FIG. 3 is a further schematic perspective view of the transformer according to the first embodiment;

(4) FIG. 4 is a schematic perspective view of a transformer comprising two electrical circuits according to a second exemplary embodiment of the invention;

(5) FIG. 5 is a schematic perspective exploded view illustrating the layers of the transformer according to the second exemplary embodiment;

(6) FIG. 6 is a schematic perspective view of the magnetic ring core and the windings of the two electrical circuits of the transformer according to the first or second or a third exemplary embodiment;

(7) FIG. 7 is a schematic perspective sectional view of the transformer according to the second exemplary embodiment;

(8) FIG. 8 is a schematic perspective sectional view of the transformer according to the first exemplary embodiment;

(9) FIG. 9 is a further schematic perspective sectional view of the transformer according to the first exemplary embodiment;

(10) FIG. 10 is a further schematic perspective sectional view of the transformer according to the first exemplary embodiment;

(11) FIG. 11 is a schematic perspective view of a transformer comprising two electrical circuits according to a third exemplary embodiment of the invention;

(12) FIG. 12 is a further schematic perspective view of a transformer comprising two electrical circuits according to the third exemplary embodiment of the invention;

(13) FIG. 13 is a schematic perspective sectional view of the transformer according to the third exemplary embodiment; and

(14) FIG. 14 is a further schematic perspective sectional view of the transformer according to the third exemplary embodiment.

DETAILED DESCRIPTION

(15) The accompanying FIGS. 2 to 14 show, by way of example, different views based on three preferred exemplary embodiments of planar, in particular intrinsically safe, transformers 100 according to the invention, which have a vertical dimension and a horizontal dimension. In the figures, the vertical dimension extends along the Y-axis, and the horizontal dimension extends along the X- and Z-axes of the coordinate system as indicated in each of FIGS. 2, 4, and 11 for the sake of clarity.

(16) The transformers 100 accordingly have a sandwich-type layer structure including a plurality of layers extending horizontally and arranged vertically on top of one another, comprising a first conductive layer 110 and a second conductive layer 120 and at least one insulating inner layer 130 disposed between the two conductive layers. Furthermore, the transformers each comprise a plurality of electrical circuits, wherein a first electrical circuit 150 and at least a second electrical circuit 160 are galvanically isolated from each other, and at least one ring-type magnetic core 140 having a hole 145, which core acts at least on the first electrical circuit 150 and on the second electrical circuit 160. The core 140 is disposed within the at least one insulating inner layer 130 in each case, and a conductor 151 of the first electrical circuit 150 and a conductor 161 of the second electrical circuit 160, i.e. a conductor provided for the current flow in the respective electrical circuit, has a respective winding 152 or 162, respectively, each comprising at least one winding turn 153 or 163, respectively. The at least one winding turn 153 of the first electrical circuit 150 and the at least one winding turn 163 of the second electrical circuit 160 each extends on the first conductive layer 110 and on the second conductive layer 120 and through the at least one insulating inner layer 130 and through the hole 145 of the core 140.

(17) A first exemplary embodiment with possible refinements is shown in FIGS. 2, 3, 6, 8, 9, and 10. A second exemplary embodiment with possible refinements is shown in FIGS. 4, 5, 6, and 7. A third exemplary embodiment with possible refinements is shown in FIGS. 6, 11, 12, 13, and 14.

(18) FIG. 1 shows a table specifying minimum distances with respect to minimum clearances and creepage distances and separation distances through solid insulation for specific levels of protection for ensuring intrinsically safe electrical circuits and hence also intrinsically safe transformers with respect to the electrical circuits thereof, and the values specified therein correspond to Table 5 of the standard EN 60079-11 applicable at the priority date of the present application, as an exemplary standard for protection in explosive atmospheres. From this table, particular minimum distances are apparent, which are therefore specified by the cited standard. These minimum distances, which will also be referred to as minimum isolation distances T0 and L0 below and in the claims, are dependent on the insulating medium, so that the minimum distances to be observed are subdivided based on solid insulation, clearance in air or creepage distances. As can be seen from the table, in a typical insulation class such as level of protection ia, ib at a voltage peak value of 375 V, hereinafter also referred to as level of protection 375 V ia, ib, the minimum separation distance for solid insulation to be observed as a minimum distance or minimum isolation distance T0 is 1 mm, for example, and the minimum creepage distance to be observed as a minimum distance or minimum isolation distance L0 is 10 mm in air and about 3.3 mm under a protective coating. Thus, for the level of protection 375 V ia, ib, a minimum separation distance corresponding to the minimum isolation distance of T0=1.0 mm has to be met within a printed circuit board, while a minimum isolation distance of L0=10.0 mm or 3.3 mm corresponding to the creepage distances in air and under a protective coating, respectively, has to be met on the outer layer of the printed circuit board.

(19) For the following description, three isolation distances are defined. Insulation distance I1 corresponds to a minimum isolation distance T0 at least required according to a required level of protection, isolation distance I2 is at least T0/2, and isolation distance I3 corresponds to a minimum isolation distance L0 at least required according to a required level of protection.

(20) As mentioned above, FIG. 2 refers to the first exemplary embodiment of a planar, intrinsically safe transformer according to the invention, which is in the form of a printed circuit board transformer here and comprises two separate electrical circuits 150 and 160, each one comprising a respective winding 152 and 162, respectively, each one with a plurality of winding turns 153 and 163 in the present example. What can be seen here of the windings are respective conductive tracks 154 of the conductor 151 of the first electrical circuit 150 and respective conductive tracks 164 of the conductor 161 of the second electrical circuit 160 along the first conductive layer 110 which is an outer layer of the printed circuit board. Here, the conductive patterns of the first electrical circuit 150 and of the second electrical circuit 160 are separated from each other in the conductive layers 110 and 120 by the third isolation distance I3, wherein I3 is equal to or greater than the specified minimum isolation distance L0. Also, the connection points between the conductive tracks 154, 164 and the conductive vias 155, 165 are clearly visible.

(21) FIG. 3 shows a possible embodiment of such a transformer based on the transformer 100 of FIG. 2, with the insulating material illustrated transparently, so that now the integrated ring-type magnetic core 140, its hole 145, and the conductive tracks 154, 164 on the second conductive layer 120 which is also an outer layer of the printed circuit board can also be seen very well. Also visible are the vias 155, 165 of the first and second electrical circuits 150, 160. The winding turns 153, 163 of windings 152, 162 of the first and second electrical circuits 150, 160 are defined by conductive tracks 154, 164 on the outer layers and by vias 155, 165 and enclose a closed magnetic core 140 which is integrated into the printed circuit board.

(22) FIG. 6 shows a possible embodiment of such a transformer based on the transformer 100 of FIG. 2, with the magnetic ring core, in particular that of FIG. 3, without insulation material and from a different perspective. Again, the windings 152, 162 of the two electrical circuits 150, 160 of the transformer 100 can be seen here. Also, terminals 156 and 166 for the external wiring (not shown) of the transformer 100 can be seen here. The components shown in FIG. 6 may also form part of the transformer according to the second or third embodiment, in the same or a very similar design and arrangement.

(23) FIGS. 8, 9, and 10 show sectional views of possible embodiments of the transformer based on the transformer 100 of FIG. 2. As can be seen here, an inner insulating layer 130 extends around the magnetic core 140 enclosing it in all spatial directions, and the thickness of this layer guarantees a second isolation distance I2 between the core and all other electrically conductive structures of the electrical circuits 150 and 160, which is equal to or greater than half the minimum isolation distance T0. The magnetic core is considered to be electrically conductive and thus to be an equipotential surface in terms of isolation. In order to obtain the minimum isolation distance of T0 for solid insulation corresponding to the minimum separation distance required by a standard, it is composed of two second isolation distances I2 as follows: An isolation distance which is at least equal to half the minimum isolation distance T0 is met everywhere between the first winding 152 and the magnetic core 140. Also, at least an isolation distance equal to half the minimum isolation distance T0 is met between the magnetic core and all other windings (e.g. second winding 162). This gives a combined isolation distance of T0/2+T0/2=T0 as required by the EN 60079-11 standard applicable at the priority date of the present application. It is important that the respective applicable standard allows for proportionate combination of isolation distances, which is often the case.

(24) The required minimum isolation distances T0 and L0 can be easily understood and verified by way of so-called minimum insulation paths between the electrical circuits 150, 160 that are isolated from each other, such as shown in FIG. 10, for example.

(25) Accordingly, a first insulation path extends from the winding 152 of the first electrical circuit 150 on the left side of the transformer 100 directly over the surface of the first conductive layer 110 to the winding 162 of the second electrical circuit 160 on the right side of the transformer. The first insulation path extends similarly also over the surface of the second conductive layer 120 (not shown). If the respective conductive layer 110 or 120 is an outer layer of the transformer 100, the shortest distance between the separated electrical circuits 150 and 160 must be equal to the third isolation distance I3, which in turn must be equal to or greater than the specified minimum isolation distance L0. For the level of protection 375 V ia, ib, for example, this shortest distance has to be at least 3.3 mm, if the respective conductive layer 110 or 120 as the outer layer of the transformer 100 is an outer layer of the printed circuit board but is coated with a special lacquer. If this lacquer coating is not provided, the shortest distance must be 10 mm instead of 3.3 mm, for example (see FIG. 1). However, a solder resist as commonly used in printed circuit board technology cannot be regarded as a protective coating in the sense of a standard and can therefore not reduce the isolation distances, for example from 10 mm to 3.3 mm. Therefore, the solder resist will not be discussed further below, although it may be employed in the exemplary embodiments. Therefore, if an outer conductive layer of the layer structure is mentioned below, this does not exclude that the conductor of the outer layer is additionally covered by a protective lacquer.

(26) A second insulation path first extends from the winding 152 of the first electrical circuit 150 on the left side of the transformer 100 through the solid insulation material of the transformer or the printed circuit board thereof to the magnetic core 140. From there, the second insulation path extends through the magnetic core (shown as a dashed line) and is not counted, and from there again through the solid insulation material to arrive at the winding 162 of the second electrical circuit 160 on the right side of the transformer 100. Both the shortest distance from the first winding 152 to the magnetic core 140 and from the magnetic core 140 to the second winding 162 must be equal to the second isolation distance I2, which is equal to half the minimum isolation distance T0. Since the minimum isolation distance T0 corresponding to the minimum separation distance for solid insulation can be combined proportionally, the required minimum insulation T0 between the two windings is resulting from 2*I2=I1, or 2*T0/2=T0, and the transformer is therefore dimensioned in compliance with the standard. The length of the second insulation path passing through the magnetic core (shown as a dashed line), is not counted here, since the magnetic core cannot be considered to be an insulating material.

(27) FIG. 4 refers to the second exemplary embodiment of a planar, intrinsically safe transformer 100 according to the invention, which suitably is again in the form of a printed circuit board transformer here and comprises two separate electrical circuits 150 and 160, each one comprising a respective winding 152 and 162, each one with a plurality of winding turns 153 and 163, respectively. In contrast to the first exemplary embodiment, the transformer shown here is constructed of a plurality of insulating inner layers 130 which are interconnected, for example by being pressed together.

(28) FIG. 5 is an exploded view of a possible embodiment based on the transformer 100 of FIG. 4, showing only the insulating layers 130 thereof, so that the three individual insulating layers 130 can be clearly seen. Here, the middle one of the three insulating layers has a recess 135 for accommodating a magnetic ring core, in which the magnetic core can be embedded (see also FIG. 6, for example).

(29) FIG. 7 shows a sectional view of the transformer in a possible embodiment based on the transformer 100 of FIG. 4. The magnetic core 140 consisting of ferrite material, for example, is embedded in a recess 135 of the middle insulating layer 130, and the recess 135 may be a cavity. Alternatively, the insulating material may also directly adjoin the magnetic core. Anyhow, the three inner insulating layers are joined to one another, in particular pressed together, so that a solid insulation material is resulting, so that a solid insulation is provided around the magnetic core 140 in all spatial directions with a thickness that guarantees a second isolation distance I2 between the core and all other electrically conductive structures of the electrical circuits 150 and 160, which is equal to or greater than half the minimum isolation distance T0.

(30) FIG. 11 refers to the third exemplary embodiment of a planar, intrinsically safe transformer 100 according to the invention, which again is suitably provided in the form of a printed circuit board transformer here and comprises two separate electrical circuits 150 and 160, each one comprising a respective winding 152 and 162, each one with a plurality of winding turns 153 and 163, respectively. In contrast to the first and second exemplary embodiments, the transformer shown here is completely integrated, which means that in addition to an insulating inner layer 130 or a plurality of insulating inner layers 130, two insulating outer layers 180 and 190 are additionally provided. In this case, the first conductive layer 110 is disposed between the insulating inner layer 130 and the insulating outer layer 180. Furthermore, the second conductive layer 120 is disposed between the insulating inner layer 130 and the insulating outer layer 190. Thus, the conductive layers 110 and 120 are covered by the insulating material of the insulating outer layers 180 and 190, respectively.

(31) FIG. 12 shows a possible embodiment based on the transformer 100 of FIG. 11, with the insulating material being shown transparently so that now the integrated ring-type magnetic core 140, its hole 145, and the conductive tracks 154, 164 of the first and second electrical circuits 150, 160 can also be see very well. Also visible are the vias 155, 165 of the first and second electrical circuits 150, 160. The winding turns 153, 163 of windings 152, 162 of the first and second electrical circuits 150, 160 are defined by conductive tracks 154, 164 along the conductive layers 110 and 120 and by vias 155, 165 and enclose a closed magnetic core 140.

(32) Since the conductive patterns of the first and second electrical circuits 150, 160 along the conductive layers 110 and 120 are now located within solid insulation material, they do no longer have to meet the third isolation distance I3 corresponding to the minimum isolation distance L0, but only the first isolation distance Il corresponding to the small minimum isolation distance T0. As a result, the transformer can be made even more compact in its horizontal dimension compared to the first and second exemplary embodiments, however at the expense of its vertical dimension which will be increased by the thickness of the additional insulating outer layers 180, 190. Alternatively, with the same horizontal dimension the transformer may accommodate more windings or winding segments and/or more winding turns compared to the first and second exemplary embodiments, while still ensuring the required minimum isolation distances.

(33) FIGS. 13 and 14 show sectional views of possible embodiments of the transformer based on the transformer 100 of FIG. 11. Clearly visible in FIG. 13 are the terminals 156 and 166 for the external wiring (not shown) of the transformer 100. In particular in FIG. 14 it can further be seen that an insulation is provided around the magnetic core 140 surrounding it in all spatial directions, which has a thickness that guarantees a second isolation distance I2 between the core and all other electrically conductive structures of the electrical circuits 150 and 160, which is equal to or greater than half the minimum isolation distance T0, and that the insulation surrounding the core 140 is composed of a plurality of interconnected insulating inner layers 130. Furthermore, it can be seen in FIG. 14 that the insulating outer layers 180 and 190 have a thickness corresponding to the second isolation distance I2.

(34) The fact that the conductive structures of the first and second electrical circuits 150, 160 along the conductive layers 110 and 120 only need to meet the first isolation distance I1 corresponding to the minimum isolation distance T0 between one another, can easily be understood and verified by way of the minimum insulation paths between the electrical circuits 150, 160 insulated from one another, shown in FIG. 14. In contrast to the first exemplary embodiment and to FIG. 10, the first insulation path according to FIG. 14 extends from the winding 152 of the first electrical circuit 150 on the left side of the transformer 100 through the solid insulating material of the insulating outer layer. From there, the first insulation path extends over the surface of the insulating outer layer (shown as a dashed line) and from there again through the solid insulating material to the winding 162 of the second electrical circuit 160 on the right side of the transformer 100. The first insulation path extends similarly also over the surface of the insulating outer layer 190 (not illustrated).

(35) Since the minimum isolation distance T0 corresponding to the minimum separation distance for solid insulation can be combined proportionally, the required minimum insulation T0 between the two windings is resulting from 2*I2=I1, or 2*T0/2=T0, and the transformer is therefore dimensioned in compliance with the standard. The length of the first insulation path passing over the surface of the insulating outer layer (shown as a dashed line) is not counted here.

(36) Generally, at least the isolation distance T0 must result in total for each possible insulation path.

LIST OF REFERENCE NUMERALS

(37) 100 Planar, in particular intrinsically safe transformer

(38) 110 First conductive layer

(39) 120 Second conductive layer

(40) 130 Insulating inner layer

(41) 135 Ring-type recess

(42) 140 Ring-type magnetic core

(43) 145 Hole of magnetic core

(44) 150 First electrical circuit

(45) 151 Conductor of first electrical circuit

(46) 152 Winding of first electrical circuit

(47) 153 Winding turn of first electrical circuit

(48) 154 Conductive track for first electrical circuit

(49) 155 Conductive via for first electrical circuit

(50) 156 Terminals for external wiring

(51) 160 Second electrical circuit

(52) 161 Conductor of second electrical circuit

(53) 162 Winding of second electrical circuit

(54) 163 Winding turn of second electrical circuit

(55) 164 Conductive track for second electrical circuit

(56) 165 Conductive via for second electrical circuit

(57) 166 Terminals for external wiring

(58) 170 Free end portion of a conductive track

(59) 180 Insulating outer layer

(60) 190 Insulating outer layer

(61) I1 First isolation distance

(62) I2 Second isolation distance

(63) I3 Third isolation distance