Method for producing a heavy-current transformer

Patent metadata

Field	Value
Publication number	US-2016322158-A1
Application number	US-201615205809-A
Country	US
Kind code	A1
Filing date	Jul 8, 2016
Priority date	Oct 31, 2011
Publication date	Nov 3, 2016
Grant date	—

Abstract

A heavy-current transformer, in particular for a power source in order to provide a welding current of a resistance welding device, with at least one primary winding and at least one secondary winding with center tapping, and a transformer element, a contact plate and a secondary winding for such a heavy-current transformer as well as a method for the manufacturing thereof, reduce losses and improve efficiency by providing at least four contacts to form a multi-point contacting, the contacts being formed by four contact faces within which the at least one primary winding and the at least one secondary winding are arranged in a series/parallel connection.

First claim

What is claimed is:

1 . A method for manufacturing a heavy-current transformer ( 12 ) comprising at least one primary winding ( 13 ) and at least one secondary winding ( 14 ) with surfaces ( 47 ) for contacting, wherein at first inner surfaces ( 47 ) of the at least one secondary winding ( 14 ) are connected with an I-beam ( 25 ) of electrically conductive material of the heavy-current transformer ( 12 ) with a first soldering material at a first, higher melting temperature (T S1 ), and subsequently at least one contact plate ( 29 ) of electrically conductive material is soldered with exterior surfaces ( 47 ) of the at least one secondary winding ( 14 ) with a second soldering material at a second melting temperature (T S2 ) that is lower as compared to the first melting temperature (T S1 ).

2 . The method according to claim 1 , wherein a circuit board ( 35 ) is connected with the at least one contact plate ( 29 ) with the first soldering material at the first, higher melting temperature (T S1 ).

3 . The method according to claim 2 , wherein after connecting the at least one contact plate ( 29 ) with the circuit board ( 35 ), circuit elements ( 24 ) are connected with the circuit board ( 35 ) and/or the contact plate ( 29 ), in particular with protrusions ( 36 ) on the contact plate ( 29 ), by using the first soldering material at the first, higher melting temperature (T S1 ).

4 . The method according to claim 3 , wherein the circuit elements ( 24 ), in particular the connections or the housings of the circuit elements ( 24 ), are connected with the surfaces ( 47 ) of the at least one secondary winding ( 14 ) with the second soldering material at the second, lower melting temperature (T S2 ).

5 . The method according to claim 1 , wherein a first soldering material at a first melting temperature between 220° C. and 300° C., in particular 260° C., and a second soldering material at a second melting temperature between 120° C. and 220° C., in particular 180° C., is used.

Assignees

• Fronius Int Gmbh

Inventors

• Artelsmair Bernhard
• Schultschik Christoph
• Neuboeck Johannes
• Wolfsgruber Stefan

Classifications

• Y10T29/49144

  by metal fusion · CPC title

• H01F41/0246

  Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36) · CPC title

• B23K11/314

  Spot welding guns, e.g. mounted on robots · CPC title

• H01F27/40

  Structural association with built-in electric component, e.g. fuse · CPC title

• H01F27/29

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