Transformer apparatus and method for manufacturing it

Abstract

A transformer apparatus (200) comprising a transformer core (210), at least one primary winding and at least one secondary winding. The transformer apparatus (200) also comprises an insert element (220), in which the at least one primary winding is arranged, and one printed circuit board (230), in which the at least one secondary winding is arranged. The insert element (220), the circuit board (230) and the transformer core (210) can hereby be coupled together or are coupled together.

Claims

1. A transformer apparatus comprising: a transformer core; at least one primary winding; at least one secondary winding; an insert element in which the at least one primary winding is arranged; and a printed circuit board, in which the at least one secondary winding is arranged, wherein the insert element, the circuit board and the transformer core are configured to be coupled with each other or are coupled with each other, and wherein the insert element comprises at least one press-fit element configured to be press-fitted into the printed circuit board to couple the insert element to the printed circuit board.

2. The transformer apparatus according to claim 1, wherein the insert element comprises at least one stranded wire and an electrically insulating material, wherein the at least one stranded wire is embedded into the electrically insulating material.

3. The transformer apparatus according to claim 1, wherein the insert element comprises a second printed circuit board into which the at least one primary winding is arranged.

4. The transformer apparatus according to claim 1, wherein the insert element features a plurality of press-fit elements, wherein at least two press-fit elements of the plurality of press-fit elements comprise electrical connections for the primary winding.

5. The transformer apparatus according to claim 1, wherein the printed circuit board comprises a plurality of layers, wherein the at least one secondary winding corresponds to at least one layer of the circuit board.

6. The transformer apparatus according to claim 1, wherein the circuit board comprises at least one through-hole plating, wherein the at least one through-hole plating extends throughout all layers of the circuit board.

7. The transformer apparatus according to claim 1, further comprising: at least one heat sink for the dissipating heat from one or both of the printed circuit board and the insert element, wherein the printed circuit board is configured to be or is arranged between the at least one heat sink and the insert element.

8. The transformer apparatus according to claim 7, further comprising: a heat conducting layer for the dissipating heat from the printed circuit board to the at least one heat sink, wherein the heat conducting layer is configured to be or is arranged between the circuit board and the at least one heat sink.

9. The transformer apparatus according to claim 2, wherein the printed circuit board comprises a plurality of layers, wherein the at least one secondary winding corresponds to at least one layer of the circuit board.

10. The transformer apparatus according to claim 3, wherein the printed circuit board comprises a plurality of layers, wherein the at least one secondary winding corresponds to at least one layer of the circuit board.

11. The transformer apparatus according to claim 4, wherein the printed circuit board comprises a plurality of layers, wherein the at least one secondary winding corresponds to at least one layer of the circuit board.

Description

(1) The invention will be explained in more detail by way of examples with reference to the attached drawings. The drawings show:

(2) FIG. 1 a schematic sectional depiction of a planar transformer;

(3) FIG. 2 a schematic sectional depiction of a transformer apparatus in accordance with one design example of the present invention;

(4) FIG. 3 a schematic sectional depiction of a partial section of the transformer apparatus from FIG. 2;

(5) FIG. 4 a schematic sectional depiction of the insert element of the transformer apparatus from FIG. 2;

(6) FIG. 5 a schematic sectional depiction of the circuit board of the transformer apparatus from FIG. 2;

(7) FIG. 6 a schematic depiction of the circuit board of the transformer apparatus from FIG. 2;

(8) FIG. 7 a schematic depiction of the insert element of the transformer apparatus from FIG. 2;

(9) FIG. 8 a flow chart of a method for the manufacturing in accordance with one design example of the present invention; and

(10) FIG. 9 a schematic depiction of an apparatus in accordance with one design example of the present invention.

(11) In the following description of preferred design examples of the present invention, identical or similar reference signs are used for the elements that are depicted in the various figures and that function in a similar manner, wherein a repeated description of these elements will be omitted.

(12) FIG. 1 depicts a schematic sectional depiction of a planar transformer 100. In other words, FIG. 1 depicts merely an 8-layer circuit board configuration of a planar transformer 100 by way of an example. In this example, the primary winding and the secondary winding of the planar transformer 100 are arranged within one single circuit board.

(13) With reference to the depiction in FIG. 1, the circuit board configuration of the PCB comprises the following layer from top to bottom: a first layer 101, a semi-finished product layer 110 or prepreg layer 110 (prepreg=preimpregnated fibers), a second layer 102, a core layer 120, a third layer 103, another semi-finished layer 110, a fourth layer 104, another core layer 120, a fifth layer 105, a further semi-finished layer 110, a sixth layer 106, a further core layer 120, a seventh layer 107, a further semi-finished layer 110 and an eighth layer 108.

(14) The second layer 102, the third layer 103, the sixth layer 106 and seventh layer 107 are hereby used for the primary winding, wherein the first layer 101, the fourth layer 104, the fifth layer 105 and the eighth layer 108 are used for the secondary winding.

(15) The circuit board configuration of the circuit board furthermore features by way of an example only one through-hole plating 130 and it exemplifies only two buried through-hole platings 140 or so-called buried vias.

(16) FIG. 2 depicts a schematic sectional depiction of a transformer apparatus 200 in accordance with one design example of the present invention. The transformer apparatus 200 comprises a transformer core 210 that is formed e.g. of ferrite. In addition to this, the transformer apparatus 200 comprises an insert element 220 in which at least one primary winding of the transformer apparatus 200 is arranged or formed. The transformer apparatus 200 also comprises a circuit board 230 in which at least one secondary winding of the transformer apparatus 200 is arranged or formed.

(17) The insert element 220, the circuit board 230 and the transformer core 210 are mechanically coupled to each other. To accomplish this, the insert element 220 and the circuit board 230 are at least partially arranged within the transformer core 210. The insert element 220 and the circuit board 230 represent separate, mutually coupled assemblies or elements. In this way the at least one primary winding and the at least one secondary winding are arranged within separate elements. In other words, the at least one primary winding is implemented by means of the insert element 220 wherein the at least one secondary winding is implemented by means of the circuit board 230. The insert element 220 and the circuit board 230 will be dealt with in more detail in the following with reference to the following figures.

(18) In accordance with the design example of the present invention that is depicted in FIG. 2, the insert element 220 comprises a plurality of press-fit elements 225, from which only two press-fit elements 225 are explicitly shown for a better representation. The press-fit elements 225 are formed in order to be pressed into the circuit board 230, in order to couple the insert element 220 with the circuit board 230. In the depiction of FIG. 2, the press-fit elements 225 are pressed into circuit board 230.

(19) In accordance with the design example of the present invention as it is depicted in FIG. 2, the transformer apparatus 200 features by way of example a heatsink 240 for the dissipation of heat from the circuit board 230 and/or from the insert element 220. The circuit board 230 is hereby arranged between the heat sink 240 and the insert element 220. The heat sink 240 is at least coupled thermally with the circuit board 230. In addition to this, the transformer apparatus 200 hereby features a heat conducting layer 250 for the dissipation of heat from circuit board 230 to the heat sink 240. The heat conducting layer 250 is arranged between the circuit board 230 and the heat sink 240. The heat conducting layer 250 is hereby designed e.g. as heat conducting foil. The heat sink 240 is thus coupled thermally at least to the circuit board 230 via the heat conducting layer 250.

(20) FIG. 3 depicts a schematic sectional depiction of a partial section of the transformer apparatus from FIG. 2. In the partial section that is depicted in FIG. 3, the transformer core 210, the insert element 220 and the circuit board 230 from the transformer apparatus are shown. The primary winding of the transformer apparatus is arranged within the insert element 220. The secondary winding of the transformer apparatus is arranged within the circuit board 230.

(21) FIG. 4 depicts a schematic sectional depiction of the insert element 220 of the transformer apparatus from FIG. 2. The primary winding 460 is also explicitly shown. The primary winding 460 is implemented by using at least one stranded wire 422 or a high frequency stranded wire 422, which is embedded into an electrically insulating material 424 as an overmolding for electrical insulation. The electrically insulating material 424 refers to e.g. a plastic material. The insert element 220 thus comprises the stranded wire 422 or the high frequency stranded wire 422 and the electrically insulating material 424. The primary winding 460 is created by means of the stranded wire 422 or the high frequency stranded wire 422.

(22) According to another design example, the insert element 220 can comprise another circuit board or be implemented as an additional circuit board, in which the primary winding is arranged.

(23) FIG. 5 depicts a schematic sectional depiction of the circuit board 230 of the transformer apparatus from FIG. 2. The circuit board 230 exemplifies an 4-layer circuit board configuration of a planar transformer with a secondary winding and without a primary winding.

(24) With reference to the depiction in FIG. 5, the circuit board configuration of the circuit board comprises the following layers from top to bottom: a first layer 531, a core layer 535, a second layer 532, a semi-finished product layer 536 or prepreg layer 536 (prepreg=preimpregnated fibers), a third layer 533, a further core layer 535 and a fourth layer 534. The circuit board 230 thus features a plurality of layers 531, 532, 533, 534, 535 and 536. The at least one secondary winding of the transformer apparatus is formed as at least one layer 531, 532, 533 and/or 534 of the circuit board.

(25) The circuit board 230 furthermore exemplifies merely one through-hole plating 537. The through-hole plating 537 extends through-out all layers 531, 532, 533, 534, 535 and 536 of the circuit board 230.

(26) FIG. 6 depicts a schematic depiction of the circuit board 230 of the transformer apparatus from FIG. 2. The circuit board 230 is hereby shown in a schematic top view or partially transparent top view. In FIG. 6, a secondary winding 670 is explicitly shown within the circuit board 230. Secondary winding 670 is formed or implemented as at least one layer, or in at least one layer of the circuit board 230.

(27) FIG. 7 depicts a schematic depiction of the insert element 220 of the transformer apparatus from FIG. 2. The insert element 220 is hereby shown in a schematic top view or partially transparent top view. From the insert element 220, a plurality of press-fit elements 225 and 725, the stranded wire 422 or the high frequency stranded wire 422, the electrically insulating material 424 and the primary winding 460 are depicted in FIG. 7.

(28) The primary winding 460 is hereby implemented in the insert element 220 by means of the high frequency stranded wire 422. The high-frequency stranded wire 422 is hereby wound several times. The high frequency stranded wire 422 is embedded or overmolded into the electrically insulating material 424.

(29) The insert element 220 features a plurality of press-fit elements 225 and 725. More specifically, the insert element 220 comprises only by way of example four press-fit elements 225 and 725. Of these, the example shows that only two press-fit elements 225 are designed for fastening the insert element 220 or for press-fitting the insert element 220 into the circuit board of the transformer apparatus. By way of example, two other press-fit elements 725 of the plurality of press-fit elements 225 and 725 are designed as electrical connections for the primary winding 460 as well as for fastening the insert element 220 or for press-fitting the insert element 220 into the circuit board of the transformer apparatus. The press-fit elements 725 are thus used both to electrically contact the primary winding 460 as well as to mechanically fix the insert element 220. In other words, electrical connections for the primary winding 460 are thus connected or combined with two press-fit elements 725.

(30) FIG. 8 depicts a flow chart of a method 800 for the manufacturing or a manufacturing method 800 in accordance with one design example of the present invention. The manufacturing method 800 can be carried out in order to produce a transformer apparatus. In more exact terms, manufacturing method 800 can be carried out to produce the transformer apparatus from FIG. 2 or a similar transformer apparatus.

(31) The manufacture 800 comprises a step 810 of forming an insert element, in which at least one primary winding of the transformer apparatus is arranged. The manufacturing method 800 also comprises a step 820 of configurating a printed circuit board, in which at least one secondary winding of the transformer apparatus is arranged. The manufacturing method 800 furthermore includes a step 830 of coupling the insert element, the circuit board, and a transformer core together.

(32) The step 810 of forming and the step 820 of configurating can be carried out in any desired order and additionally or alternatively at least partially at the same time.

(33) According to one design example, at least one stranded wire can be embedded into an electrically insulating material in the step 810 of forming. Alternatively, another circuit board with the at least one secondary winding can be configured in the step 810 of forming.

(34) FIG. 9 depicts a schematic depiction of an apparatus 900 in accordance with one design example of the present invention. Apparatus 900 is designed as a control unit. Apparatus 900 is configured to initiate or control the manufacturing of a transformer apparatus. More specifically, apparatus 900 is designed to initiate or control the manufacturing of the transformer apparatus from FIG. 2 or of a similar transformer apparatus.

(35) Apparatus 900 is connected to a manufacturing system 950 in such a manner, that a transmitting of signals can be carried out. The manufacturing system 950 features by way of example only one first machine 960, one second machine 970 and one third machine 980.

(36) Apparatus 900 comprises a forming device 910, which is designed to control the first machine 960 in order to form the insert element, in which at least one primary winding of the transformer apparatus is arranged. Apparatus 900 furthermore comprises a configuration device 920, which is designed to control the second machine 970 for the configurating of a circuit board, in which at least one secondary winding of the transformer apparatus is arranged. Furthermore, apparatus 900 comprises a coupling device 930, which is designed to control the third machine 970 for the mutual coupling of the insert element, the circuit board and a transformer core.

(37) If a design example includes an “and/or” linking between a first characteristic and a second characteristic, this can be read in such a way that the design example according to one embodiment features both the first characteristic as well as the second characteristic and according to another embodiment either only the first characteristic or only the second characteristic.

LIST OF REFERENCE SIGNS

(38) 100 planar transformer 101 first layer 102 second layer 103 third layer 104 fourth layer 105 fifth layer 106 sixth layer 107 seventh layer 108 eighth layer 110 semi-finished layer or prepreg layer 120 core layer or core 130 through-hole plating 140 buried through-hole plating 200 transformer apparatus 210 transformer core 220 insert element 225 press-fit element 230 circuit board 240 heat sink 250 heat conducting layer 422 stranded wire 424 electrically insulating material 460 primary winding 531 first layer 532 second layer 533 third layer 534 fourth layer 535 core layer 536 semi-finished layer or prepreg layer 537 through-hole plating 670 secondary winding 725 press-fit element 800 method for manufacturing or manufacturing method 810 step of forming 820 step of configuring 830 step of mutual coupling 900 apparatus 910 forming device 920 configuring device 930 coupling device 950 manufacturing system 960 first machine 970 second machine 980 third machine