Transformer module and power module

Patent metadata

Field	Value
Publication number	US-12080465-B2
Application number	US-201916671153-A
Country	US
Kind code	B2
Filing date	Oct 31, 2019
Priority date	Nov 2, 2018
Publication date	Sep 3, 2024
Grant date	Sep 3, 2024

Abstract

A transformer module and a power module are provided. The transformer module includes: a magnetic core, a first winding and a second winding. The magnetic core includes at least one magnetic column at least partially covered by a multi-layer carrier including a plurality of horizontal copper foils and connecting copper foils. Horizontal copper foils are located on horizontal wiring layers, and connecting copper foils are disposed to connect horizontal copper foils. First and second windings surround the magnetic column, and the second winding is located outside the first winding. Both the first and second windings are formed by a horizontal copper foil and a connecting copper foil; two ends of the first winding are electrically connected to first and second surface-mounted pins; two ends of the second winding are electrically connected to third and fourth surface-mounted pins; these pins are disposed on at least one surface of the transformer module.

First claim

What is claimed is:

1. A transformer module, comprising:
a magnetic core, comprising at least one magnetic column being at least partially covered by a multi-layer carrier, wherein the multi-layer carrier comprises a plurality of horizontal foils and a plurality of connecting foils, each of the horizontal foils is located on a horizontal wiring layer, and the connecting foil is disposed to connect the horizontal foils located on different horizontal wiring layers; and
a first winding and a second winding surrounding the magnetic column, and the second winding being located outside the first winding;
wherein the first winding comprises at least two horizontal foils of the plurality of the horizontal foils and at least two connecting foils of the plurality of the connecting foils; the second winding comprises at least two horizontal foils of the plurality of the horizontal foils and at least two connecting foils of the plurality of the connecting foils;
a first end of the first winding is electrically connected to a first pin by a first connection piece; a second end of the first winding is electrically connected to a second pin by a second connection piece; and the first connection piece and the second connection piece pass through an insulating layer between the first winding and the second winding;
a first end of the second winding is electrically connected to a third pin; a second end of the second winding is electrically connected to a fourth pin;
the first pin, the second pin, the third pin and the fourth pin are disposed on at least one surface of the transformer module.

2. The transformer module according to claim 1 , wherein a transition layer is formed on a surface of the magnetic column by spraying, dipping, electrophoresis, electrostatic spraying, chemical vapor deposition, physical vapor deposition or evaporation with an insulating material, and the first winding is formed on the transition layer;
the second winding is a multi-turn winding, and a connecting comprised in each turn of the multi-turn winding is waist-shaped hole copper.

3. The transformer module according to claim 1 , wherein the multi-layer carrier comprises a first carrier and a second carrier;
wherein the first carrier and the second carrier are oppositely disposed; the first carrier comprises a first horizontal wiring layer, a first insulating layer and a second horizontal wiring layer which are sequentially disposed, the second carrier comprises a third horizontal wiring layer, a second insulating layer and a fourth horizontal wiring layer which are sequentially disposed; the first horizontal wiring layer is in contact with the third horizontal wiring layer, and an accommodating groove is formed in the first insulating layer and the second insulating layer to accommodate at least part of the magnetic column;
the horizontal foils of the first winding comprise a first foil and a fourth foil, the connecting foils of the first winding comprise a second foil, a third foil, a fifth foil and a sixth foil;
the first foil is disposed on the second horizontal wiring layer, and comprises a first segment and a second segment spaced apart from each other to respectively form the first end and the second end of the first winding; the second foil and the third foil are disposed penetrating the first insulating layer and are both electrically connected to the first foil; the fourth foil is disposed on the fourth horizontal wiring layer, and the fifth foil and the sixth foil are disposed penetrating the second insulating layer and are both electrically connected to the fourth foil; the first foil, the second foil, the third foil, the fourth foil, the fifth foil and the sixth foil are connected to each other and surround the accommodating groove.

4. The transformer module according to claim 3 , wherein the first carrier further comprises a third insulating layer and a fifth horizontal wiring layer outside the second horizontal wiring layer;
the second carrier further comprises a fourth insulating layer and a sixth horizontal wiring layer outside the fourth horizontal wiring layer;
the horizontal foils of the second winding comprise a seventh foil and a tenth foil, and the connecting foils of the second winding comprise an eighth foil, a ninth foil, an eleventh foil and a twelfth foil;
wherein the seventh foil is located on the fifth horizontal wiring layer, and comprises a third segment and a fourth segment spaced apart from each other to respectively form the first end and the second end of the second winding; the tenth foil is located on the sixth horizontal wiring layer; the seventh foil, the eighth foil, the ninth foil, the tenth foil, the eleventh foil and the twelfth foil are connected to each other and surround the accommodating groove.

5. The transformer module according to claim 4 , wherein,
the transformer module further comprises a third winding, wherein the third winding comprises at least two horizontal foils of the plurality of the horizontal foils and at least two connecting foils of the plurality of the connecting foils, and the third winding is located outside the second winding;
a first end of the third winding is electrically connected to a fifth pin;
a second end of the third winding is electrically connected to the second pin, and the first pin, the second pin and the fifth pin are disposed on a surface of the transformer module; or
a second end of the third winding is electrically connected to a sixth pin, and the first pin, the second pin, the fifth pin and the sixth pin are disposed on the at least one surface of the transformer module
the first carrier further comprises a fifth insulating layer and a seventh horizontal wiring layer outside the fifth horizontal wiring layer;
the second carrier further comprises a sixth insulating layer and an eighth horizontal wiring layer outside the sixth horizontal wiring layer;
the horizontal foils of the third winding comprise a thirteenth foil and a sixteenth foil, and the connecting foils of the third winding comprise a fourteenth foil, a fifteenth foil, a seventeenth foil and an eighteenth foil;
the thirteenth foil is located on the seventh horizontal wiring layer, and comprises a fifth segment and a sixth segment spaced apart from each other to respectively form the first end and the second end of the third winding; the sixteenth foil is located on the eighth horizontal wiring layer; the thirteenth foil, the fourteenth foil, the fifteenth foil, the sixteenth foil, the seventeenth foil and the eighteenth foil are connected to each other and surround the accommodating groove.

6. The transformer module according to claim 1 , wherein from a first preset temperature to a second preset temperature, an equivalent coefficient of thermal expansion of an insulating layer between the first winding and the magnetic column is higher than an equivalent coefficient of thermal expansion of an insulating layer between the first winding and the second winding; or
a decomposition temperature of an insulating layer between the first winding and the magnetic column is 170° ° C.-260° C.; or
a low-melting-point material is disposed between the magnetic column and an insulating layer between the first winding and the magnetic column, and a melting temperature of the low-melting-point material is lower than 200° C.

7. The transformer module according to claim 6 , wherein the transformer module further comprises an exhaust passage disposed to penetrate a portion between a surface of the magnetic column and a surface of the transformer module.

8. A power module, comprising:
a transformer module according to claim 1 ; and
a switching module, wherein the switching module is in contact with the transformer module and electrically connecte

Assignees

• Delta Electronics Shanghai Co

Inventors

• Cai Chaofeng
• Zeng Jianhong
• Hong Shouyu
• Wu Rui
• Ye Haoyi
• Ye Yiqing
• Xin Xiaoni

Classifications

• H01F27/32

  Insulating of coils, windings, or parts thereof · CPC title

• H01F27/292

  Surface mounted devices · CPC title

• H01F41/0233

  Manufacturing of magnetic circuits made from sheets (magnetic cores made from sheets H01F27/245; soft magnetic alloys in the form of sheets H01F1/16) · CPC title

• H01F27/027

  specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards · CPC title

• H01F27/2895

  Windings disposed upon ring cores · CPC title