Planar transformer for energy transfer

Patent metadata

Field	Value
Publication number	US-11101063-B2
Application number	US-201615579777-A
Country	US
Kind code	B2
Filing date	May 19, 2016
Priority date	Jun 5, 2015
Publication date	Aug 24, 2021
Grant date	Aug 24, 2021

Abstract

A planar transformer for power transmission, having vertical and horizontal extents, includes a circuit board having a sandwich-type structure with at least three layers to form electrical conductors. First and second layers of these layers form outer layers of the circuit board, and each additional one of these layers forms an inner layer of the circuit board. An insulation material with a minimum thickness is arranged between all of these layers, with a number of at least three mutually galvanically isolated circuits. A first circuit forms a primary circuit and each additional circuit forms an equally entitled secondary circuit, having a magnetic core assembled from two interconnected magnetic core parts. A first core part with a central part and two outer legs forms a U shape. The circuit board has two recesses, and the two outer legs of the first core part are inserted into these recesses and connected to the second core part at their ends remote from the central part. A conductor is formed on at least one of the outer layers for exactly one single circuit of the at least three circuits, and a conductor of at least one circuit of the at least three circuits is wound around a first outer leg, and conductors of at least two additional circuits of the at least three circuits are wound around the second outer leg.

First claim

The invention claimed is:

1. A planar transformer for power transmission, having a vertical extent and a horizontal extent, comprising:
a circuit board having a sandwich-type structure with at least three layers having electrical conductors disposed thereon, wherein a first layer and a second layer of the layers form first and second exterior layers of the circuit board, and each additional one of the layers forms an inner layer of the circuit board, and wherein an insulation material with a minimum thickness is arranged between all of the layers,
a number of at least three mutually galvanically isolated circuits wherein only one of the circuits forms a primary circuit of the planar transformer and the other ones of the circuits forms a first secondary circuits the planar transformer, and wherein electric current is fed in through the primary circuit for power transmission and an output current is topped from the secondary circuits,
a magnetic core, which at least partially encloses the circuit board and acts on the primary circuit and on at least two of the secondary circuits,
wherein the magnetic core is comprised of two interconnected magnetic core parts, wherein a first one of the core parts forms a U shape having only first and second outer legs, the first outer leg disposed at a first end of the first one of the core parts, the second outer leg disposed at a second end of the first one of the core parts, and a central part extending from the first outer leg to the second outer leg, and wherein the circuit board has only two recesses, and the first and second outer legs of the first one of the core parts are inserted into these recesses and connected to the second one of the core parts at their free ends remote from the central part,
wherein a first one of the electrical conductors is disposed on an exterior surface of the first exterior layer of the circuit board and a second one of the electrical conductors is disposed on an exterior surface of the second exterior layer of the circuit board, wherein only the first and second ones of the electrical conductors form only a first one of the at least three mutually galvanically isolated circuits,
wherein each of the at least two other of the at least three mutually galvanically isolated circuits includes at least another one of the electrical conductors, wherein the electrical conductors of the at least two other of the at least three mutually galvanically isolated circuits are disposed on the inner layers of the circuit board,
wherein the first electrical conductor disposed on the exterior surface of the first exterior layer and the second electrical conductor disposed on the second exterior surface of the circuit board are wound around only one of the first and second outer legs, and the at least another one of the electrical conductors of a second one of the at least two other of the at least three mutually galvanically isolated circuits is wound around the second outer leg, and the at least another one of the electrical conductors of a third one of the at least two other of the at least three mutually galvanically isolated circuits is wound around the first outer leg, and
wherein the first and second electrical conductors formed on the exterior surfaces the first and second exterior layers is are each covered by a protective coating.

2. The planar transformer according to claim 1 , wherein the planar transformer is integrated into a housing of an isolation amplifier.

3. The planar transformer according to claim 1 , wherein the core is to be associated with a potential of one of the first and second electrical conductors formed on the corresponding one of the first and second exterior layers with respect to the galvanic isolation of the circuits.

4. The planar transformer according to claim 1 , wherein for each of the electrical conductors formed on one of the layers of the circuit board, at least one end is electrically connected to a via, wherein the via is electrically connected to a connection arranged in another one of the layers for electrical contacting of the conductor.

5. The planar transformer according to claim 4 , wherein the via is passed completely through all the layers of the circuit board and is lined with electrically conductive material.

6. The planar transformer according to claim 4 , wherein a predetermined minimum distance between an air and creep zone and two of the circuits defines the minimum distance between the via of one of the circuits and the edges of the two recesses.

7. The planar transformer according to claim 4 , wherein a via belonging to a conductor wound around one of the outer legs is always arranged in the interior of the conductor wound around that one of the outer legs.

8. A planar transformer for power transmission, having a vertical extent and a horizontal extent, comprising:
a circuit board having a sandwich-type structure with at least three layers having electrical conductors disposed thereon, wherein a first layer and a second layer of the layers form first and second exterior layers of the circuit board, and each additional one of the layers forms an inner layer of the circuit board, and wherein an insulation material with a minimum thickness is arranged between all of the layers,
a number of at least three mutually galvanically isolated circuits wherein only one of the circuits forms a primary circuit of the planar transformer and the other ones of the circuits forms secondary circuits the planar transformer, and wherein electric current is fed in through the primary circuit for power transmission and an output current is topped from the secondary circuits,
a magnetic core, which at least partially encloses the circuit board and acts on the primary circuit and on at least two of the secondary circuits,
wherein the magnetic core is comprised of two interconnected magnetic core parts, wherein a first one of the core parts forms a U shape with a central part and first and second outer legs, and wherein the circuit board has two recesses, and the first and second outer legs of the first one of the core parts are inserted into these recesses and connected to the second one of the core parts at their ends remote from the central part,
wherein a first one of the electrical conductors is disposed on an exterior surface of the first exterior layer of the circuit board and a second one of the electrical conductors is disposed on an exterior surface of the second exterior layer of the circuit board, wherein only the first and second ones of the electrical conductors form only a first one of the at least three mutually galvanically isolated circuits,
wherein each of the at least two other of the at least three mutually galvanically isolated circuits includes at least another one of the electrical conductors, wherein the electrical conductors of the at least two other of the at least three mutually galvanically isolated circuits are disposed on the inner layers or a same one of the inner layers of the circuit board,
wherein the first electrical conductor disposed on the exterior surface of the first exterior layer and the second electrical conductor disposed on the second exterior surface of the circuit board are wound around only the first outer leg, and the at least another one of the electrical conductors of a second one of the at least two other of the at least three mutually galvanically isolated circuits is wound around one of the first and second outer legs, and
wherein the first and second electrical conductors formed on the exterior surfaces the first and second exterior layers are each covered by a protective coating.

9. The planar transformer according to claim 8 , wherein the electrical conductors of the at least two other of the at le

Assignees

• Phoenix Contact Gmbh & Co

Inventors

• Scholz Peter

Classifications

• H01F27/2804 Primary

  Printed windings · CPC title

• H01F2019/085

  Transformer for galvanic isolation · CPC title

• H01F2027/065

  Mounting on printed circuit boards · CPC title

• H01F27/29

  Terminals; Tapping arrangements {for signal inductances} · CPC title

• H01F2027/2819

  Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit · CPC title