Transformer module and power module

Patent metadata

Field	Value
Publication number	US-12159749-B2
Application number	US-202318493818-A
Country	US
Kind code	B2
Filing date	Oct 25, 2023
Priority date	Nov 2, 2018
Publication date	Dec 3, 2024
Grant date	Dec 3, 2024

Abstract

The present disclosure provides a transformer module and a power module, wherein the transformer module comprises: a magnetic core, a first wiring layer, a first insulating layer and a second wiring layer, where 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, where at least part of the first metal winding is 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, where the second metal winding is at least partially covered by the first insulating layer, and 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, wherein at least part of the first metal winding is 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, 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, the second metal winding comprises a first end and a second end, the first end and the second end of the second metal winding are electrically connected to the first pin and the second pin through a first connector and a second connector respectively, and at least one of the first connector and the second connector passes through and is 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 at least one of the first connector and the second connector also passes 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 first pin and the second pin are located on a first side of the transformer module for connection to an external circuit.

5. The transformer module according to claim 1 , wherein the turns of the second metal winding is larger than or equal to the turns of the first metal winding.

6. The transformer module according to claim 1 , wherein at least part of the second metal winding is wound around the magnetic core in the foil structure.

7. The transformer module according to claim 1 , wherein the transformer module further comprises a third pin and a fourth pin, and the first end and the second end of the first metal winding respectively connected to the third pin and the fourth pin.

8. The transformer module according to claim 7 , wherein the first, second, third and fourth pins are surface-mounted pins.

9. The transformer module according to claim 7 , 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 second metal winding; and
length of the second pin being greater than or equal to a half of length of the second metal winding;
length of the third pin being greater than or equal to a half of length of the first metal winding; and
length of the fourth pin being greater than or equal to a half of length of the first metal winding.

10. The transformer module according to claim 7 , 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 second 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 second 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 first 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 first metal winding.

11. 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, wherein at least part of the first metal winding is 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, 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, the second metal winding comprises a first end and a second end, the first end and the second end of the second metal winding are electrically connected to the first pin and the second pin through a first connector and a second connector respectively, and at least one of the first connector and the second connector passes through the first insulating layer and at least part of the projection of the first and second connectors in the first wiring layer is covered by the first metal winding;
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.

12. The transformer module according to claim 11 , wherein both of the first connector and the second connector also pass through the first wiring layer.

13. The transformer module according to claim 11 , wherein the first connector and the second connector are vias.

14. The transformer module according to claim 11 , wherein the first pin and the second pin are located on a first side of the transformer module for connection to an external circuit.

15. The transformer module according to claim 11 , wherein the transformer module further comprises a third pin and a fourth pin, and the first end and the second end of the first metal winding respectively connected to the third pin and the fourth pin.

16. The transformer module according to claim 11 , wherein at least part of the second winding is wound around the magnetic core in the foil structure.

17. The transformer module according to claim 15 , 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 second metal winding;
length of the second pin being greater than or equal to a half of length of the second metal winding;
length of the third pin being greater than or equal to a half of length of the first metal winding; and
length of the fourth pin being greater than or equal to a half of length of the first metal winding.

18. The transformer module according to claim 15 , 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 second metal winding;
the second pin being plural, and total length of the second pins being greater than or equal to a h

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

• H01F41/04

  for manufacturing coils {(coils for transformer or inductances H01F27/28)} · 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

• H01F30/08

  without magnetic core · CPC title

• H01F41/064

  Winding non-flat conductive wires, e.g. rods, cables or cords · CPC title

• H01F41/063

  with insulation · CPC title