Flat voltage transformer

Abstract: A low-profile, high-frequency power transformer comprises one or more insulated ferrite slabs (12). In one embodiment a pair of slots (14,16) are defined through the or a stacked array of insulated slabs. A single-turn metallic ribbon conductor (22,24) is then looped through each pair of slots to form a corresponding first and second loop which are coupled in a magnetic flux circuit with each other through the stack. The distance separating one pair of slots (14) is different from the distance separating the other pair of slots (16) so that the loops formed by the ribbons have a corresponding unequal cross-section. Hence the ratio of the voltages on the ribbons is proportional to the ratio of the respective cross-sectional areas of the ribbon loops. In another embodiment, a third ribbon is added having a cross-sectional loop area equivalent to the second ribbon to provide symmetrical single-turn, output coils.

Description: The present invention relates to planar transformers comprising a magnetic core and windings disposed through apertures in the core and starts from the US-A-4'206'434. A classical transformer comprises a magnetic core of any one of a large variety of shapes around which is wound two or more coils. One of the coils is used as an input coil and is defined as the primary winding. The other coil is used as an output coil and is defined as the secondary winding. There may be in fact any combination of multiple input and output windings dependent upon the desired application. Since the windings are wrapped around the same magnetic core, whatever its shape may be, the effective areas of cross section of the windings are approximately the same. Therefore, the voltage transformation which is achieved by the primary and secondary windings depends upon the ratio of their turns. A number of problems arise in high frequency power applications of transformers. Typically the number of turns in the primary or secondary windings is such that high resistive losses are encountered. Although these losses can usually be accepted in low power low frequency applications, in higher frequency applications the physics of electrical conduction in the windings is qualitatively different in that skin effects and proximity effects preclude the efficient use of the total wire cross section. The resistive losses thus become exaggerated at high frequencies. Moreover, because of the multiple number of turns in each of the windings on the transformer, it is difficult to manufacture a low profile or planar power transformer. The ability to manufacture a planar power transformer is particularly accentuated where multiple output coils are required on the transformer. The prior art has devised a number of designs wherein multiple slabs of magnetic material are utilised as the core structure for a transformer. Examples can be seen in HASE, "Regulating Transformer with Magnetic Shunt", US-A-4,206,434 (1980); KOUYOUMJIAN. "Electric Control Apparatus", US-A-1,910,172 (1933); STIMLER, "Alternating Electric Current Transformer", US-A-2,598,617 (1952); and DOWLING, "Electrical Translating Apparatus", US-A-1,793,312 (1931). However, the electrical transforming function which has been performed by the US-A-4'206'434 prior art transformer for example still depends upon the ratio of turns of the primary and secondary coils, and is thus subject to each of the high frequency defects discussed above Moreover, although the US-A-4'206'434 prior art transormer has an aspect ratio which makes it wider and taller than it is thick the transformer is not extremely thin or flat. Therefore, what is needed is a design for an electrical transformer which allows the transformer to be both extremely slim or flat and/or which can be utilised in high frequency applications without suffering the defects of prior art transformers. According to the present invention there is provided a planar transformer having a magnetic core including at least one planar slab with apertures defined through said core and windings disposed through said apertures, characterised in that said slab has first and second pairs of slots defined therethrough, said slots of said first pair being separated from each other within said slab by a first corresponding predetermined distance and said slots of said second pair of slots being separated from one another within said slab by a second predetermined distance different from said first predetermined distance, further characterised in that a first conductor is disposed through said first pair of slots to form a first loop, said loop having one dimension approximately equal to said first predetermined distance and still further characterised in that a second conductor is disposed through said second pair of slots and forms a second loop having at least one dimension approximately equal to said second predetermined distance, said first and second loops being magnetically coupled with each other through said slab for providing magnetic coupling between said loops with a voltage ratio between said loops approximately equal to the ratio of said first and second predetermined distances. The transformer core may comprise a plurality of planar slabs, each slab having defined therethrough corresponding first and second pairs of slots and with the first and second conductors being disposed through corresponding ones of the slots to form the corresponding first and second loops through all of the plurality of slabs. Each slab of a plurality of planar slabs may be insulatively separated by an insulating layer having high thermal conductivity so that heat is readily conducted out of the plurality of slabs. Each insulating layer may comprise BeO and AlN in laminate form. In carrying out the invention each of the core slabs may be thin and flat, preferably ferromagnetic, so that a low-profile transformer is provided with minimal conductive losses through the conductors at high frequencies due to skin and proximity effect, and with minimal eddy current losses within the plurality of slabs. The conductors of the transformer may comprise flat ribbon conductors of amorphous metal. In order that the invention and its various other preferred features may be understood more easily some embodiments thereof will now be described, by way of example only, with reference to the drawings wherein like elements are referenced by like numerals and in which:- Figure 1 is a diagrammatic perspective view of a first embodiment of the invention, Figure 2 is a plan view of one of a plurality of ferrite cores utilised in the embodiment shown in Figure 1, Figure 3 is a sectional view taken through lines 3-3 of the ferrite core of Figure 2, Figure 4 is a diagrammatic perspective view of a second embodiment of the invention. A low-profile, high-frequency power transformer comprises a plurality of insulated planar ferrite slabs formed in a stacked array.In one embodiment a pair of slots are defined through the stacked array of insulated slabs. A single-turn metallic ribbon conductor is then looped through each pair of slots to form a corresponding first and second loop which are coupled in a magnetic flux circuit with each other through the stack. The distance spearating one pair of slots is unequal to the distance separating the other pair of slots so that the loops formed by the ribbons have a corresponding unequal cross section. Hence the ratio of the voltages on the ribbons is proportional to the ratio of the respective cross-sectional areas of the ribbon loops. In another embodiment, a third ribbon is added having a cross-sectional loop area equaivalent to the second ribbon to provide symmetrical, single-turn output coils. The first embodiment of the invention shown in Figure 1 can have one or more ferrite slabs, collectively denoted by reference numeral 10. Where a plurality of slabs are employed, they are stacked one on top of the other or one behind the other to form a flat array. Each individual slab, denoted by reference numeral 12, is electrically insulated from the others either by the simple expedient of a gap as diagrammatically depicted in Figure 1, or preferably by a thin interlying layer of insulating material (not shown). The insulating material may have a thin laminate or coating on each slab 12 with a high thermal conductivity to allow for improved thermal conduction away or heat sinking from the transformer. Suitable insulating layers include BeO and A1N in laminate form. Alternatively, slabs 12 may comprise amorphous metal sheets similarly insulated one from another. At least two sets of slots 14 and 16 are defined through each of slabs 12. In the illustrated embodiment of Figure 1, slots 14 are defined through the upper portion of each slab 12 and separated by a predetermined distance 18. Lower set of slots 16 are defined through the lower portion of slabs 12, as shown in Figure 1, and separated by a predetermined distance 20. It is a feature of the invention that distances 18 and 20 are unequal. In any case, sets of slots 14 and 16 are identically defined through each of the slabs 12 comprising the selective stack 10. In the illustrated embodiment, distance 18 is greater than distance 20 and in fact is twice as great. A first conductive ribbon 22 is provided as an input circuit or coil and is led through each of slots 14 on the left hand edges of slabs 12 as shown in Figure 1, across the back of the rearmost slab 12 (not shown) and back through the rightmost slots 14 to form a return lead. Thus, ribbon 22 comprises a single loop through slots 14 in collection 10 of slabs 12. Similarly, a second conductive ribbon 24 is similarly disposed through leftmost lower slot 16, through collection 10 of slabs 12, across the back of rearmost slab 12 and outwardly through the rightmost slots 16 to form a return lead. Ribbon 24 thus forms a second conductive loop which is coupled through the magnetic circuit provided by collection 10 of slabs 12 with the loop formed by first ribbon 22. Ribbons 22 and 24 are fabricated from metallic sheet material typically 0.00254-to-0.0254 cm (0.001-to-0.01") thick. In the preferred embodiment ribbons 22 and 24 comprise a metal such as copper. Although not depicted in the diagrammatic illustration of Figure 1, ribbons 22 and 24 may also include insulative coatings, layers or coverings which prevent shorting across the loop formed by ribbons 22 and 24 or other stray conductions through collection 10 of slabs 12. Figure 2 is a plan top view of one of the ferrite slabs 12 as shown in Figue 1. Figure 3 is a cross-sectional view taken through the bent section lines 3-3 of Figure 2 so that a sectional view through each slot 14 and 16 is depicted. Figure 1 illustrates that in the case of a ribbon loop placed through slots 14 and 16, which have a significantly greater width than the thickness of the ribbon, that the distances 20 and 18 must be measured from corresponding sides of each of the respective slots. More particularly, in Figure 2 distance 18 is measured from each of the left sides of slots 14 and 16, since ribbons 22 and 24 are led into and out of stack 10 from the left side and hence are pulled during fabrication to the left side of each slot. Clearly, the distances would be differently defined if other fabrication techniques were utilised, such as leading ribbons 22 and 24 in both from the right side or in from the left and out from the right, and vice versa. Even though in the illustrated embodiment of Figure 1 there is only a single loop formed by ribbons 22 and 24, the input-to-output voltage ratio is nevertheless two to one. This is due to the fact that the cross-sectional area encompassed within collection 10 of slabs 12 by the loop formed by ribbon 22 is twice as large as that formed by the loop of ribbon 24. This surprising result, that is the high voltage ratio despite a single loop, is obtained because the distance between top slots 14 is about twice the distance between bottom slots 16. The output-to-input voltage ratio can thus be varied to obtain even greater or lesser ratios depending upon the ratio of distances 18 and 20. Although the ratio is not infinitely expandable, it is expected that input-to-output voltage ratios of the order of magnitude of 5 can be practically. obtained with a device constructed according to the teaching of Figure 1. The invention further has the advantage that input and output of ribbon connectors 22 and 24 are as stated, made from sheet conductors, in the illustrated embodiment, ribbons 0.508 cm (0.2") wide and 0.00762 cm (0.003") thick. This minimises conduction losses by reducing skin and proximity effects, and therefore creates greater current carrying capacity. For example, a conventional circular wire having the same cross-sectional area as that of a ribbon conductor 0.00762 cm (0.003") thick and 0.508 cm (0.2") wide could be expected to have 300 percent higher losses. Still further, the invention allows an inherently flat or planar structure. Not only is the collective stack or collection 10 of slabs 12 substantially thinner than conventional cores, the addition of ribbon conductors 22 and 24 add negligibly to the overall thickness of the transformer. However, no matter how thin the transformer becomes, the input-to-output voltage ratio is not significantly affected. In fact it is expected that there will be no effect upon voltage transformation characteristics with transformers as thin as 0.1270 cm (0.05") utilising one or more slabs 12. Still further, the use of laminated ferrite for each slab 12 reduces eddy current losses wthin the ferrite material. These eddy current losses are very significant at high frequencies, amounting to as much as 50.80 percent energy loss at 500-1000 kHz. On the other hand, a device made according to the invention can result in 50 percent or more reduction in eddy current losses, utilising 0.1270 cm (0.05") thick ferrite slabs. In certain applications, there is a need to connect a multiple number of identical electronic circuits or loads in parallel in order to increase the overall power which can be delivered to the collective load. A single turn transformer, as described in connection with Figure 1, offers a significant advantage in that, if such multiple load units are driven by the same transformer of the type as depicted and described below in connection with Figure 4, the transformer design assures that the load is shared equally by each of the electronic circuits. Therefore, the load and electronic stress, such as heat dissipation and the like, placed on any one of the individual circuits, will be reduced and the overall reliability of the product maximised. Turning now to Figure 4, a perspective view of a diagrammatic depiction of such a dual output, single turn transformer is shown, generally denoted by reference numeral 30. Transformer 30 similarly includes one or more ferrite slabs 32, four being illustrated. The or each slab is/are of generally the same composition and arrangement as described previously in connection with Figures 1 to 3. However, slabs 32 of Figure 4 include a plurality of slots three being illustrated as 34,36 and 38. In the illustrated embodiment slots 34 and 38 are all identical to slot 36 defined through the middle of each slab 32 with slot 34 on the left and slot 38 on the right as depicted in Figure 4. A metallic input ribbon 40 is provided and disposed through leftmost slots 34 in slabs 32, across the back of the rearmost slab 32, and forwardly through the rightmost slots 38 of slabs 32 to form a return lead. However, transformer 30 includes two output conductors, namely ribbons 42 and 44. Output ribbon 42 is similarly disposed through leftmost slot 34 of each slab 32, across the back of the rearmost slab 32, but is then brought forwardly through centre slot 36 in each of slabs 32 and outwardly to the left to form a return lead as depicted in Figure 4. Similarly, output ribbon 44 is disposed through the rightmost slot 38 of each slab 32, across the back of the rearmost slab 32, and then forwardly through centre slot 36 to form a return lead to the right, as depicted in Figure 4. Transformer 30 is now provided with two symmetrical single turn output loops, each having approximately one half the cross-sectional area of the input loop formed by ribbon 40. However, due to the symmetry of the output loops formed by ribbons 42 and 44, the power which is delivered to a first and second load coupled respectively to ribbons 42 and 44 is similarly symmetrical or equal. It must be expressly understood that the embodiment of Figure 4 may be extended to include even more output loops, odd or even in total number, which could be disposed in a similar manner through slots 34,36 and 38 either by forming one or more loops above those formed by ribbons 42 and 44 or by placing additional ribbons insulated one from the other on top of or concentrically within the loops depicted in Figure 4 by ribbons 42 and 44.

Claims: A planar transformer having a magnetic core including at least one planar slab (12) with apertures defined through said core and windings disposed through said apertures, characterised in that said slab has first and second pairs of slots (14,16) defined therethrough, said slots of said first pair (14) being separated from each other within said slab by a first corresponding predetermined distance (18) and said slots of said second pair of slots (16) being separated from one another within said slab (12) by a second predetermined distance (20) different from said first predetermined distance, further characterised in that a first conductor (22) is disposed through said first pair of slots to form a first loop, said loop having one dimension approximately equal to said first predetermined distance (18) and still further characterised in that a second conductor (24) is disposed through said second pair of slots and forms a second loop having at least one dimension approximately equal to said second predetermined distance (20), said first and second loops being magnetically coupled with each other through said slab for providing magnetic coupling between said loops with a voltage ratio between said loops approximately equal to the ratio of said first and second predetermined distances. A planar transformer according to claim 1, characterised in that the magnetic core comprises a plurality of planar slabs (12), each slab having defined therethrough corresponding first and second pairs of slots (14,16), and said first and second conductors (22,24) being disposed through corresponding ones of said slots to form said corresponding first and second loops through all of said plurality of slabs (12). A planar transformer according to claim 2, characterised in that each of said plurality of planar slabs (12) is electrically insulated from an adjacent slab or slabs by an interlying insulating layer between each of said slabs (12), said interlying layer having a high thermal conductivity so that heat transfer out of said transformer is maximised. A planar transformer according to claim 2 or 3, characterised in that each planar slab (12) is thin and flat, so that a thin low-profile transformer is provided with minimal conductive losses through said conductors at high frequencies due to skin and proximity effect, and with minimal eddy current losses within the plurality of said slabs (12). A planar transformer according to claim 4, characterised in that each said slab (12) is ferromagnetic. A planar transformer according to any preceding claim, characterised in that each conductor (22,24) is a flat metallic ribbon. A planar transformer according to claim 3, characterised in that each insulating layer is comprised of BeO and AlN in laminate form.

Inventors: REGELMAN DALE FRANCIS, ROSHEN WASEEM AHMED, TURCOTTE DAVID EARNEST, REGELMAN, DALE FRANCIS, ROSHEN, WASEEM AHMED, TURCOTTE, DAVID EARNEST
Applicants: INT STANDARD ELECTRIC CORP, INTERNATIONAL STANDARD ELECTRIC CORPORATION
Application year: 1989
Main classification: H01F19
IPC codes: H01F30, H01F27, H01F19