Electrical transformer

• US 20040150502A1
• Filed: 02/04/2003
• Published: 08/05/2004
• Est. Priority Date: 02/04/2003
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Chignola, Bruce William, Jacobson, Boris Solomon, Wesolowski, William Edward, Martin, Kevin Edward, Dakessian, Garo, Kling, Dennis Robert, Praeger, Eberhardt
• Granted Patent: US 6,952,153 B2
• Time in Patent Office: Days
• US Class Current: 336/200
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 17/062 Toroidal core with turns of coil around it
• CPC Class Codes: H01F 2038/006 matrix transformer consisting of several interconnected individual transformers working as a whole

Abstract

An electrical transformer having a core disposed between a pair of dielectrics. The first dielectric has a plurality of first electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such first dielectric. The second dielectric board is disposed over, and is in registration with, the first dielectric. The second dielectric has a plurality of second electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such second dielectric. The core has an aperture therein. The aperture extends between the first and second dielectrics. A dielectric body is disposed in the aperture. The body has disposed therein a plurality of third electrically isolated electrical conductor segments. First ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of first electrically isolated electrical conductor segments. Second ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of second electrically isolated electrical conductor segments. A primary winding of the transformer comprises first ones of the first electrically isolated electrical conductor segments, first ones of the second electrically isolated electrical conductor segments, and first ones of the third electrically isolated electrical conductor segments. A secondary winding comprises second ones of the first electrically isolated electrical conductor segments, second ones of the second electrically isolated electrical conductor segments, and second ones of the third electrically isolated electrical conductor segments. The first and second multilevel printed circuit boards are disposed in a pair of overlaying planes and the plurality of third electrically isolated electrical conductor segments are disposed perpendicular to the overlaying planes. The primary and secondary winding provide loops around the core. The third electrically isolated electrical conductor segments are embedded within the core.

Claims

1. An electrical transformer, comprising:

a first dielectric having a plurality of first electrically isolated electrical conductor segments disposed on the dielectric;

a second dielectric, disposed over, and in registration with, the first dielectric, such second dielectric having a plurality of second electrically isolated electrical conductor segments disposed on the second dielectric;

a core having an aperture therein, such aperture extending between the first and second dielectrics;

a plurality of third electrically isolated electrical conductor segments; and

wherein first ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of first electrically isolated electrical conductor segments and second ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of second electrically isolated electrical conductor segments to provide a portion of a primary winding and a portion of a secondary winding for the transformer;

wherein such primary winding comprises first ones of the first electrically isolated electrical conductor segments, first ones of the second electrically isolated electrical conductor segments, and first ones of the third electrically isolated electrical conductor segments; and

wherein such secondary winding comprises second ones of the first electrically isolated electrical conductor segments, second ones of the second electrically isolated electrical conductor segments, and second ones of the third electrically isolated electrical conductor segments.

2. The electrical transformer recited in claim 1 wherein the first and second dielectrics are disposed in a pair of overlaying planes and wherein the plurality of third electrically isolated electrical conductor segments are disposed perpendicular to the overlaying planes.

3. The electrical transformer recited in claim 2 wherein the primary and secondary winding provide loops around the core.

4. The electrical transformer recited in claim 3 wherein the third electrically isolated electrical conductor segments are disposed within the core.

5. The electrical transformer recited in claim 4 wherein the core comprises a toroidal shaped body and wherein core is disposed in a central region of the toroidal shaped body.

6. An electrical transformer, comprising:

a first dielectric having a plurality of first electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such first dielectric;

a second dielectric, disposed over, and in registration with, the first dielectric, such second dielectric having a plurality of second electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such second dielectric;

a plurality of third electrically isolated conductor segments;

a plurality of fourth electrically isolated conductor segments;

wherein the plurality of third and fourth conductors segments are disposed between the first dielectric and the second dielectric; and

wherein first ends of the third electrically isolated electrical conductor segments and first ends of the fourth electrically isolated electrical conductor segments are electrically connected to the plurality of first electrically isolated electrical conductor segments and second ends of the third electrically isolated electrical conductor segments and the fourth electrically isolated electrical conductor segments are electrically connected to the plurality of second electrically isolated electrical conductor segments to provide a primary winding and a secondary winding for the transformer;

wherein such primary winding comprises first ones of the first electrically isolated electrical conductor segments, first ones of the second electrically isolated electrical conductor segments, and first ones of the third and fourth electrically isolated electrical conductor segments; and

wherein such secondary winding comprises second ones of the first electrically isolated electrical conductor segments, second ones of the second electrically isolated electrical conductor segments, and second ones of the third and fourth electrically isolated electrical conductor segments.

7. The electrical transformer recited in claim 6 wherein the first and second dielectrics are disposed in a pair of overlaying planes and wherein the plurality of third and fourth electrically isolated electrical conductor segments are disposed perpendicular to the overlaying planes.

8. The electrical transformer recited in claim 7 including a core is disposed between the first and second dielectrics and wherein the primary and secondary winding provide loops around the core.

9. The electrical transformer recited in claim 8 wherein the third and fourth electrically isolated electrical conductor segments are embedded within the core. 10. The electrical transformer recited in claim 9 wherein the core comprises a pair of adjacent, toroidal shaped bodies and each one of the third and fourth electrically isolated conductive segments is disposed in a central region of a corresponding one of the pair of toroidal shaped bodies.

10. An electrical transformer, comprising:

a first multilayer printed circuit board having a plurality of first electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such first multilevel printed circuit board;

a second multilayer printed circuit board, disposed over, and in registration with, the first multilevel printed circuit board, such second multilevel printed circuit board having a plurality of second electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such second multilevel printed circuit board;

a core having an aperture therein, such aperture extending between the first and second multilevel printed circuits boards;

a dielectric body disposed in the aperture, such body having disposed therein a plurality of third electrically isolated electrical conductor segments; and

wherein first ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of first electrically isolated electrical conductor segments and second ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of second electrically isolated electrical conductor segments to provide a portion of a primary winding and a portion of a secondary winding for the transformer;

wherein such primary winding comprises first ones of the first electrically isolated electrical conductor segments, first ones of the second electrically isolated electrical conductor segments, and first ones of the third electrically isolated electrical conductor segments; and

wherein such secondary winding comprises second ones of the first electrically isolated electrical conductor segments, second ones of the second electrically isolated electrical conductor segments, and second ones of the third electrically isolated electrical conductor segments.

11. The electrical transformer recited in claim 10 wherein the first and second multilevel printed circuit boards are disposed in a pair of overlaying planes and wherein the plurality of third electrically isolated electrical conductor segments are disposed perpendicular to the overlaying planes.

12. The electrical transformer recited in claim 11 wherein the primary and secondary winding provide loops around the core.

13. The electrical transformer recited in claim 12 wherein the third electrically isolated electrical conductor segments are embedded within the core.

14. The electrical transformer recited in claim 13 wherein the core material comprises a toroidal shaped body and wherein dielectric body is disposed in a central region of the toroidal shaped body.

15. An electrical transformer, comprising:

a first multilayer printed circuit board having a plurality of first electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such first multilevel printed circuit board;

a second multilayer printed circuit board, disposed over, and in registration with, the first multilevel printed circuit board, such second multilevel printed circuit board having a plurality of second electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such second multilevel printed circuit board;

a pair of dielectric bodies disposed between the first multilevel printed circuit board and the second multilevel printed circuit board, each one of such bodies having disposed therein a plurality of third electrically isolated electrical conductor segments; and

wherein first ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of first electrically isolated electrical conductor segments and second ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of second electrically isolated electrical conductor segments to provide a primary winding and a secondary winding for the transformer;

wherein such primary winding comprises first ones of the first electrically isolated electrical conductor segments, first ones of the second electrically isolated electrical conductor segments, and first ones of the third electrically isolated electrical conductor segments; and

wherein such secondary winding comprises second ones of the first electrically isolated electrical conductor segments, second ones of the second electrically isolated electrical conductor segments, and second ones of the third electrically isolated electrical conductor segments.

16. The electrical transformer recited in claim 15 wherein the first and second multilevel printed circuit boards are disposed in a pair of overlaying planes and wherein the plurality of third electrically isolated electrical conductor segments are disposed perpendicular to the overlaying planes.

17. The electrical transformer recited in claim 16 including a core material disposed between the first and second multilevel printed circuit boards and wherein the primary and secondary winding provide loops around the core material.

18. The electrical transformer recited in claim 17 wherein the third electrically isolated electrical conductor segments are embedded within the core material.

19. The electrical transformer recited in claim 18 wherein the core material comprises a pair of adjacent, toroidal shaped bodies and each one of the a pair of dielectric bodies is disposed in a central region of a corresponding one of the pair of toroidal shaped bodies.

20. An electrical transformer structure, comprising:

a first multilayer printed circuit board having a plurality of first electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such first multilevel printed circuit board;

a second multilayer printed circuit board, disposed over, and in registration with, the first multilevel printed circuit board, such second multilevel printed circuit board having a plurality of second electrically isolated electrical conductor segments disposed on each one of a plurality of electrically isolated levels of such second multilevel printed circuit board;

a dielectric spacer member disposed between the first multilevel printed circuit board and the second multilevel printed circuit board, such spacer member having a plurality of apertures therethrough, such apertures passing between a top and a bottom surface of the spacer member;

a plurality of toroidal shaped cores, each one of such cores being disposed in a corresponding one of the plurality of apertures of the dielectric spacer member, each one of the cores having an aperture therein, the apertures of the cores being coaxial with the apertures in the dielectric spacer member;

a plurality of dielectric bodies, each one of such dielectric bodies being disposed in a corresponding one of the apertures in the cores;

a plurality of plurality of dielectric bodies having a corresponding one of the sets of third electrically isolated electrical conductor segments;

wherein first ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of first electrically isolated electrical conductor segments and second ends of the third electrically isolated electrical conductor segments are electrically connected to the plurality of second electrically isolated electrical conductor segments to provide a primary winding and a secondary winding for the transformer;

wherein such primary winding comprises first ones of the first electrically isolated electrical conductor segments, first ones of the second electrically isolated electrical conductor segments, and first ones of the third electrically isolated electrical conductor segments; and

wherein such secondary winding comprises second ones of the first electrically isolated electrical conductor segments, second ones of the second electrically isolated electrical conductor segments, and second ones of the third electrically isolated electrical conductor segments.

21. The electrical transformer recited in claim 20 wherein the first and second multilevel printed circuit boards are disposed in a pair of overlaying planes and wherein the plurality of third electrically isolated electrical conductor segments are disposed perpendicular to the overlaying planes.

22. The electrical transformer recited in claim 21 including wherein the primary and secondary winding provide loops around the cores.