Transformer module and power module

Patent metadata

Field	Value
Publication number	US-11450480-B2
Application number	US-201916671158-A
Country	US
Kind code	B2
Filing date	Oct 31, 2019
Priority date	Nov 2, 2018
Publication date	Sep 20, 2022
Grant date	Sep 20, 2022

Abstract

The present disclosure provides a transformer module and a power module, wherein the transformer module comprises: a magnetic core, a first metal winding and a second metal winding. A first wiring layer, a first insulating layer and a second wiring layer are sequentially disposed on the magnetic core from the outside to the inside; the first metal winding is formed on the first wiring layer and winded around the magnetic core in a foil structure; the first insulating layer is at least partially covered by the first metal winding; a second metal winding is formed on the second wiring layer and winded around the magnetic core in a foil structure, wherein the second metal winding is at least partially covered by the first insulating layer, and is at least partially covered by the first metal winding.

First claim

What is claimed is:

1. A transformer module, comprising:
a magnetic core, a first wiring layer, a first insulating layer and a second wiring layer, wherein the first wiring layer, the first insulating layer and the second wiring layer are sequentially disposed on the magnetic core from outside to inside;
a first metal winding, formed in the first wiring layer and wound around the magnetic core in a foil structure;
the first insulating layer, at least partially covered by the first metal winding;
a second metal winding, formed in the second wiring layer and wound around the magnetic core in the foil structure, wherein the second metal winding is at least partially covered by the first insulating layer, and at least partially covered by the first metal winding;
wherein, the transformer module further comprises a first pin, a second pin, a third pin, and a fourth pin, the first metal winding comprises a first end and a second end, the second metal winding comprises a first end and a second end, the first end and the second end of the first metal winding respectively connected to the first pin and the second pin, the first end and the second end of the second metal winding are electrically connected to the third pin and the fourth pin through a first connector and a second connector respectively, and both of the first connector and the second connector pass through and are at least partially surrounded by the first insulating layer;
wherein the dimension of the winding parallel to the longitudinal direction of the magnetic column is W, the thickness of the winding which is the dimension of the winding vertical to the magnetic column of the magnetic core is H, when H and W satisfy the relationship: W>10H, the winding has the foil structure.

2. The transformer module according to claim 1 , wherein both of the first connector and the second connector also pass through the first wiring layer.

3. The transformer module according to claim 1 , wherein the first connector and the second connector are vias.

4. The transformer module according to claim 1 , wherein the second metal winding, the first connector, the second connector, the third pin and the forth pin are in one piece.

5. The transformer module according to claim 1 , wherein the first connector and the second connector are formed by cutting the second metal winding, and the third pin and the fourth pin are formed by folding the first connector and the second connector, respectively.

6. The transformer module according to claim 1 , wherein the first pin, the second pin, the third pin, the fourth pin are located on a first side of the transformer module for connection to an external circuit.

7. The transformer module according to claim 1 , wherein the magnetic core is further provided with a second insulating layer and a third wiring layer sequentially, and the second insulating layer is at least partially covered by the second metal winding;
the transformer module further comprises:
a third metal winding, formed in the third wiring layer and wound around the magnetic core in the foil structure, wherein the third metal winding is at least partially covered by the second insulating layer; and
a fifth pin;
wherein, the third metal winding comprises a first end and a second end, the first end of the third metal winding is electrically connected to the fifth pin through a third connector, and the second end of the third metal winding is electrically connected to the first pin.

8. The transformer module according to claim 7 , wherein the third connector is via.

9. The transformer module according to claim 7 , wherein the number of turns of the first metal winding is one turn, the number of turns of the second metal winding is a plurality of turns, and the number of turns of the third metal winding is one turn.

10. The transformer module according to claim 7 , wherein the fifth pin is located between the first pin and the second pin.

11. The transformer module according to claim 10 , wherein the transformer module comprises a plurality of the fifth pins, and the second pin further comprises a plurality of teeth, and the plurality of teeth and the plurality of fifth pins are alternately arranged.

12. The transformer module according to claim 7 , wherein the magnetic core comprises a window, wherein on the first side, the fifth pin is a C-shape or -shape pin surrounding the window, the first pin is a C-shape or -shape pin surrounding the window, and the second pin is a C-shape or -shape pin surrounding the window.

13. The transformer module according to claim 1 , wherein
length of a pin and length of a metal winding meet a proportional relationship as at least one of the following:
length of the first pin being greater than or equal to a half of length of the first metal winding;
length of the second pin being greater than or equal to a half of length of the first metal winding;
length of the third pin being greater than or equal to a half of length of the second metal winding; and
length of the fourth pin being greater than or equal to a half of length of the second metal winding.

14. The transformer module according to claim 1 , wherein
length of pins and length of a metal winding meet a proportional relationship as at least one of the following:
the first pin being plural, and total length of the first pins being greater than or equal to a half of length of the first metal winding;
the second pin being plural, and total length of the second pins being greater than or equal to a half of length of the first metal winding;
the third pin being plural, and total length of the third pins being greater than or equal to a half of length of the second metal winding; and
the fourth pin being plural, and total length of the fourth pins being greater than or equal to a half of length of the second metal winding.

15. The transformer module according to claim 1 , wherein the first insulating layer includes a base insulating layer and an auxiliary insulating layer.

16. The transformer module according to claim 1 , wherein the base insulating layer is an electric technology, and the auxiliary insulating layer is an insulating glue locally arranged.

17. A power module, comprising:
the transformer module according to claim 1 ;
a switch module, wherein the switch module is in contact with the first side of the transformer module and is electrically connected to the first pin and/or the second pin.

18. The power module according to claim 17 , wherein the switch module comprises a board and at least one power switch, the power switch is disposed on the board or embedded in the board, and the power switch is electrically connected to the first pin and/or the second pin.

19. The power module according to claim 18 , wherein the power module further comprises a capacitor module, the capacitor module is located on the board and adjacent to the transformer module, and the capacitor module is electrically connected to the switch module;
or the capacitor module is on the same side of the switch module on the carrier board and adjacent to the switch module;
or the capacitor module is buried in the carrier board;
or the capacitor module is located in a window of the transformer module;
or the capacitor module is located on an upper surface of the transformer module;
or the capacitor module is located below the power switch.

20. The power module according to claim 17 , wherein the magnetic core of the transformer module is further provided with a second insulating layer a

Assignees

• Delta Electronics Shanghai Co

Inventors

• Cai Chaofeng
• Xin Xiaoni
• Zeng Jianhong
• Hong Shouyu
• Wu Rui
• Ye Haoyi
• Ye Yiqing
• Zhou Jinping
• Fu Zhiheng
• Zhou Min
• Kuo Yu-Ching
• Pan tong-sheng
• Lin Wen-Yu

Classifications

• H01F27/2895

  Windings disposed upon ring cores · CPC title

• H01F2027/2857

  Coil formed from wound foil conductor · CPC title

• H01F41/0213

  Manufacturing of magnetic circuits made from strip(s) or ribbon(s) (magnetic cores made by winding a ribbon H01F27/25) · CPC title

• H01F27/2804 Primary

  Printed windings · CPC title

• H01F30/08

  without magnetic core · CPC title