Embedded magnetic component transformer device

Patent metadata

Field	Value
Publication number	US-2016111965-A1
Application number	US-201514883855-A
Country	US
Kind code	A1
Filing date	Oct 15, 2015
Priority date	Oct 17, 2014
Publication date	Apr 21, 2016
Grant date	—

Abstract

An embedded transformer device includes first, second, and auxiliary windings, defined in an insulating substrate by conductive vias joined together by conductive traces. The positions of the conductive vias are arranged to optimize the isolation properties of the transformer and to reduce the coupling of the transformer by increasing the leakage inductance. The embedded transformer device provides better isolation between input side and output side windings, and allows an oscillating LC circuit to be set up in the case of a short circuit, preventing high power from extending between the input and output terminals and thereby avoiding damage to the connected electrical components.

First claim

1 . An embedded transformer device, comprising:
an insulating substrate including a first side and a second side opposite the first side, and including a cavity therein, the cavity including an inner and an outer periphery; a magnetic core housed in the cavity including a first section and a second section; a first winding extending through the insulating substrate and around the first section of the magnetic core; and a second winding extending through the insulating substrate and around the second section of the magnetic core; wherein the first winding and the second winding are located in separate regions from each other in the insulating substrate; each of the first and second windings include:
upper conductive traces located on the first side of the insulating substrate;
lower conductive traces located on the second side of the insulating substrate;
inner conductive connectors extending through the insulating substrate adjacent to an inner periphery of the magnetic core, the inner conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive traces; and
outer conductive connectors extending through the insulating substrate adjacent to an outer periphery of the magnetic core, the outer conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive traces;
the inner conductive connectors of the first winding are arranged in a plurality of curved rows, each of the plurality of curved rows being positioned at a constant or substantially constant distance from an inner periphery of the cavity; the inner conductive connectors of the second winding are arranged in a first curved row positioned at a constant or substantially constant distance from the inner periphery of the cavity that is large enough to allow a second curved row of inner conductive connectors to be accommodated between the first curved row and the inner periphery of the cavity; and the outer conductive connectors of the second winding are arranged in a first curved row positioned at a constant or substantially constant distance from the outer periphery of the cavity that is large enough to allow a second curved row of outer conductive connectors to be accommodated between the first curved row and the outer periphery of the cavity.

2 . The embedded transformer device of claim 1 , wherein:
the inner conductive connectors of the first winding on a curved row closest to the inner periphery of the cavity are arranged on a first circular or substantially circular arc having a first radius; the inner conductive connectors of the second winding on the first curved row are arranged on a second circular or substantially circular arc, concentric to the first circular or substantially circular arc, having a second radius; and the first radius is greater than the second radius.

3 . The embedded transformer device of claim 1 , wherein the first winding is spaced apart from the second winding so that electrical isolation is provided between the first winding and the second winding.

4 . The embedded transformer device of claim 1 , wherein the first winding does not overlap with the second winding in a thickness direction of the insulating substrate.

5 . The embedded transformer device of claim 1 , further comprising:
a first isolation barrier located on the first side of the insulating substrate, covering at least a portion of the first side between the first winding and the second winding where the first winding and second winding are closest, and defining a solid bonded joint with the first side of the insulating substrate; and a second isolation barrier located on the second side of the insulating substrate covering at least a portion of the second side between the first winding and the second winding where the first winding and second winding are closest, and defining a solid bonded joint with the second side of the insulating substrate.

6 . The embedded transformer device of claim 1 , further comprising:
an auxiliary winding, extending through the insulating substrate and around the magnetic core, the auxiliary winding including:
upper conductive traces located on the first side of the insulating substrate;
lower conductive traces located on the second side of the insulating substrate;
inner conductive connectors extending through the insulating substrate adjacent to the inner periphery of the magnetic core, the inner conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive traces; and
outer conductive connectors extending through the insulating substrate adjacent to the outer periphery of the magnetic core, the outer conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive traces; wherein
the inner conductive connectors of the auxiliary winding are arranged in a plurality of curved rows, each of the plurality of curved rows being positioned at a constant or substantially constant distance from the inner periphery of the cavity.

7 . The embedded transformer device of claim 6 , wherein the auxiliary winding is spaced apart from the second winding so that electrical isolation is provided between the auxiliary winding and the second winding.

8 . The embedded transformer device of claim 1 , wherein electrical isolation is provided by a minimum of:
a minimum distance of separation between the first winding and the second winding; and a minimum distance of separation between the second winding and the magnetic core.

9 . The embedded transformer device of claim 1 , wherein the constant or substantially constant distance being large enough to allow a second curved row of outer conductive connectors to be accommodated increases a leakage inductance of the transformer device.

10 . The embedded transformer device of claim 1 , wherein a leakage inductance of the transformer device and a distributed capacitance of the first and second windings define a high-frequency oscillating LC circuit, operable to limit power transfer between the first and second windings when a short circuit occurs.

11 . A power converter comprising the embedded transformer device of claim 1 .

12 . The power converter of claim 11 , further comprising circuitry to energize the first and second windings, wherein the circuitry is a Royer circuit.

13 . An embedded transformer device, comprising:
an insulating substrate including a first side and a second side opposite the first side, and including a cavity therein, the cavity including an inner and an outer periphery; a magnetic core housed in the cavity including a first section and a second section; a first winding, extending through the insulating substrate and around the first section of the magnetic core; a second winding, extending through the insulating substrate and around the second section of the magnetic core; wherein the first winding and the second winding are located in separate regions from each other in the insulating substrate; each of the first and second windings includes:
upper conductive traces located on the first side of the insulating substrate;
lower conductive traces located on the second side of the insulating substrate;
inner conductive connectors extending through the insulating substrate adjacent to an inner periphery of the magnetic core, the inner conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive trac

Assignees

• Murata Manufacturing Co

Inventors

• Wang Jing
• Kneller Quinn
• Parish Scott

Classifications

• H01F41/125 Primary

  Other insulating structures; Insulating between coil and core, between different winding sections, around the coil · CPC title

• H02M3/33538

  of the forward type (H02M3/3353, H02M3/33569 take precedence) · CPC title

• H01F27/324

  Insulation between coil and core, between different winding sections, around the coil; Other insulation structures · CPC title

• H01F2027/2809

  on stacked layers · CPC title

• H01F41/041 Primary

  Printed circuit coils (apparatus or processes for manufacturing printed circuits in general H05K3/00) · CPC title