TRANSFORMER AND ASSOCIATED METHOD OF MAKING

• US 20080007382A1
• Filed: 07/06/2006
• Published: 01/10/2008
• Est. Priority Date: 07/06/2006
• Status: Active Grant

• Current Assignee: North South Holdings Incorporated (Spherix Incorporated)
• Original Assignee: Harris Corporation (L3Harris Technologies, Inc.)
• Inventors: SNYDER, Steven R.
• Granted Patent: US 7,449,987 B2
• Time in Patent Office: Days
• US Class Current: 336/200
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 30/04 having two or more secondary windings, each supplying a separate load, e.g. for radio set power supplies
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A transformer and method of making same is disclosed. A substantially planar configured, first half primary winding and first half secondary winding are formed over a substantially planar base. The first half primary and secondary windings are overlaid with a ferrite layer A substantially planar configured, second half primary winding and second half secondary winding are formed over the ferrite layer in stacked relation to the respective first half primary winding and secondary windings The respective first and second half primary windings and respective first and second half secondary windings are interconnected together.

Claims

1. A method of making a transformer, which comprises:

forming a substantially planar configured, first half primary winding and first half secondary winding over a substantially planar base;

applying a ferrite layer over the first half primary and secondary windings;

forming a substantially planar configured, second half primary winding and second half secondary winding over the ferrite layer in stacked relation to the respective first half primary and secondary windings; and

interconnecting respective first and second half primary windings and respective first and second half secondary windings.

2. The method according to claim 1, which further comprises forming the first half and second half primary windings, followed by forming the first half and second half secondary windings

3. The method according to claim 1, which further comprises printing as metallic circuits the first and second half primary and secondary windings.

4. The method according to claim 3, which further comprises interconnecting the respective first and second half primary windings and respective first and second half secondary windings by overprinting on a ferrite layer the respective second half primary winding and second half secondary winding.

5. The method according to claim 1, which further comprises interconnecting the respective first and second half primary windings and respective first and second half secondary windings using conductive vias.

6. The method according to claim 1, which further comprises forming the substantially planar base as a thick film ceramic material.

7. The method according to claim 1, which further comprises forming the substantially planar base as a unfired ferrite tape.

8. A method of making a transformer, which comprises:

printing a first half primary winding as a metallic circuit on a thick film ceramic substrate;

applying a ferrite layer on the first half primary winding;

printing a second half primary winding as a metallic circuit on the ferrite layer;

applying a dielectric material to form a cavity structure;

printing a first half secondary winding as a metallic circuit on the dielectric material;

applying a second ferrite layer on the first half secondary winding;

printing a second half secondary winding on the ferrite layer; and

interconnecting the respective first and second half primary windings and respective first and second half secondary windings.

9. A method according to claim 8, which further comprises connecting the ends of respective first and second half primary windings and first and second half secondary windings by leaving exposed ends and overprinting the respective second half primary and secondary windings on the ferrite layers such that ends of second half primary and secondary windings connect exposed ends of the respective first half primary and secondary windings.

10. A method according to claim 8, which further comprises extending the respective ferrite layers to cover the first half primary and secondary windings and forming conductive vias within the ferrite layers that interconnect respective first half primary and secondary windings and second half primary and secondary windings.

11. A method according to claim 8, which further comprises forming the ferrite layer as a ferrite paste.

12. A method of making a transformer, which comprises:

printing first half primary and secondary windings as metallic conductors on an unfired ferrite tape material such that secondary windings are positioned in spaced relation to the primary windings;

applying a substantially planar ferrite layer on the first half primary and secondary windings, said ferrite layer having conductive vias that interconnect ends of first half primary and secondary windings; and

printing second half primary and secondary windings on the ferrite layer such that ends of the windings coincide with conductive vias, wherein respective first and second half primary and secondary windings are interconnected together by said conductive vias

13. A method according to claim 12, which further comprises forming the conductive vias as plated through holes.

14. A method according to claim 12, which further comprises forming the ferrite layer as a ferrite paste.

15. A transformer comprising:

a substantially planar base;

a substantially planar configured first half primary winding and first half secondary winding supported by the substantially planar base;

at least one ferrite layer formed over the first half primary winding and first half secondary winding;

a substantially planar configured second half primary winding and second half secondary winding formed over the ferrite layer in stacked relation to respective first half primary and secondary windings and interconnected together.

16. The transformer according to claim 15, wherein said base is formed from a thick film ceramic material.

17. The transformer according to claim 15, wherein said base is formed from an unfired ferrite tape.

18. The transformer according to claim 15, wherein said primary and secondary windings comprise printed circuit patterns.

19. The transformer according to claim 15, wherein said printed circuit patterns forming second half primary and secondary windings overlap a ferrite layer to interconnect respective first half primary and secondary windings.

20. The transformer according to claim 15, and further comprising conductive vias interconnecting said first and second half primary windings and first and second half secondary windings.

21. A transformer comprising:

a thick film ceramic substrate;

a first half primary winding printed on the thick film ceramic substrate;

a ferrite layer formed over the first half primary winding;

a second half primary winding printed on the ferrite layer and interconnecting said first half primary winding;

a dielectric material formed over the second half primary winding;

a first half secondary winding printed on the dielectric material;

a second ferrite layer formed over the first half secondary winding; and

a second half secondary winding printed on the ferrite layer and interconnecting said first half secondary winding.

22. The transformer according to claim 21, wherein said second half primary and secondary windings are overprinted on the respective ferrite layers to interconnect said first half primary and secondary windings.

23. The transformer according to claim 21, and further comprising conductive vias formed within said ferrite layers and interconnecting said first half primary and secondary windings and respective second half primary and secondary windings.

24. A transformer comprising:

an unfired ferrite tape;

first half primary and secondary windings printed on the unfired ferrite tape such that the secondary windings are received in spaced relation to the primary windings;

a ferrite layer formed on the first half primary and secondary windings and having conductive vias that interconnect ends of first half primary and secondary windings;

second half primary and secondary windings printed on the ferrite layer such that ends of the windings engage conductive vias wherein said windings are interconnected together by said conductive vias.

25. The transformer according to claim 24, wherein said conductive vias are formed as plated through holes.