Method for producing a heavy-current transformer

• US 10,325,720 B2
• Filed: 07/08/2016
• Issued: 06/18/2019
• Est. Priority Date: 10/31/2011
• Status: Active Grant

• Current Assignee: Fronius International GmbH (G&K Privatstiftung)
• Original Assignee: Fronius International GmbH (G&K Privatstiftung)
• Inventors: Artelsmair, Bernhard, Schultschik, Christoph, Neuboeck, Johannes, Wolfsgruber, Stefan
• Primary Examiner(s): Tugbang, A. Dexter
• Application Number:
  US15/205,809
• Publication Number:
  US 20160322158A1
• Time in Patent Office: 1,075 Days
• CPC Class Codes: B23K 11/241 Electric supplies B23K11/248 takes precedence
• CPC Class Codes: B23K 11/314 Spot welding guns, e.g. mounted on robots
• CPC Class Codes: H01F 27/08 Cooling heat-transfer elements F28F; Ventilating structural details of casings H01F27/02
• CPC Class Codes: H01F 27/16 Water cooling
• CPC Class Codes: H01F 27/20 Cooling by special gases or non-ambient air
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 38/085 Welding transformers
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01F 41/0246 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 Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: H05K 1/18 Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 2201/1003 Non-printed inductor
• CPC Class Codes: H05K 3/34 by soldering
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49144 by metal fusion

Abstract

A method for manufacturing a heavy-current transformer with at least one primary winding and at least one secondary winding with surfaces for contacting connects first inner surfaces of the at least one secondary winding with an I-beam of electrically conductive material of the heavy-current transformer with a first soldering material at a first, higher melting temperature, and subsequently at least one contact plate of electrically conductive material is soldered with exterior surfaces of the at least one secondary winding with a second soldering material at a second melting temperature that is lower as compared to the first melting temperature.

Claims

1. A method for manufacturing a heavy-current transformer for a power source in order to provide a welding current to a resistance welding device, the heavy-current transformer comprising at least one primary winding and at least one secondary winding the method comprising:

connecting first inner surfaces of the at least one secondary winding with an I-beam of electrically conductive material of the heavy-current transformer by using a first soldering material at a first, higher melting temperature, and

subsequently soldering at least one contact plate of electrically conductive material with exterior surfaces of the at least one secondary winding by using a second soldering material at a second melting temperature that is lower as compared to the first melting temperature,

wherein the at least one secondary winding is arranged within a recess of the I-beam, the first inner surfaces of the at least one secondary winding form first contacts directly connected to the I-beam, and the exterior surfaces of the at least one secondary winding form second contacts directly connected to the at least one contact plate.

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

3. The method according to claim 2, wherein after connecting the at least one contact plate with the circuit board, circuit elements are connected with the circuit board or the contact plate by using the first soldering material at the first, higher melting temperature.

4. The method according to claim 3, wherein the circuit elements are connected with the exterior surfaces of the at least one secondary winding by using the second soldering material at the second melting temperature.

5. The method according to claim 3, wherein after connecting the at least one contact plate with the circuit board, the circuit elements are connected with protrusions on the contact plate by using the first soldering material at the first, higher melting temperature.

6. The method according to claim 3, wherein connections or housings of the circuit elements are connected with the exterior surfaces of the at least one secondary winding by using the second soldering material at the second melting temperature.

7. The method according to claim 1, wherein the first soldering material at the first, higher melting temperature is between 220°

C. and 300°

C. and the second soldering material at the second melting temperature is between 120°

C. and 220°

C.

8. The method according to claim 7, wherein the first higher melting temperature is 260°

C. and the second melting temperature is 180°

C.

9. The method according to claim 1, wherein the heavy-current transformer is dimensioned so that the welding current provided to the resistance welding device is 20 kA to 30 kA.