Transformer and inductor modules having directly bonded terminals and heat-sink fins

• US 6,578,253 B1
• Filed: 05/02/1994
• Issued: 06/17/2003
• Est. Priority Date: 10/04/1991
• Status: Expired due to Fees

• Current Assignee: FMTT, Inc.
• Original Assignee: FMTT, Inc.
• Inventors: Herbert, Edward
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US08/236,378
• Time in Patent Office: 3,333 Days
• Field of Search: 296/021, 296/05, 336/192, 336/210, 336/61, 336/60
• US Class Current: 29/605
• CPC Class Codes: H01F 2038/006 matrix transformer consisting of several interconnected individual transformers working as a whole
• CPC Class Codes: H01F 27/06 Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 5/04 Arrangements of electric connections to coils, e.g. leads
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

A matrix transformer and/or inductor module has its terminations bonded rigidly to the ferrite core of which it is made. Because the ferrite core is strong and dimensionally stable, the terminations are rugged and precisely located, important criteria for assembly to printed circuit boards and the like, especially if automated assembly methods are used. In another embodiment, the module has top and bottom metal plates which are the high current output terminals. This module can be mounted sandwiched between live heat sinks. In another embodiment, deep grooves are made into the core material, and fins are bonded into the grooves. The grooves reduce core losses by reducing eddy currents and dimensional resonance effects, and the fins remove heat from within the core allowing operation at much higher flux density and frequency.

Claims

1. A method of manufacturing a module having at least one solid magnetic core, said at least one solid magnetic core having an electrically insulating top surface and an electrically insulating bottom surface, said module comprising at least one of a transformer module and an inductor module and said module having at least a first and a second electrical output for connecting said module to circuitry external to said module, said method comprising the steps of:

obtaining said at least one solid magnetic core;

obtaining an electrically conductive base plate that is dimensioned to cover said bottom surface of said at least one solid magnetic core, said base plate being manufactured of a material having sufficient electrical conductivity to allow said base plate to serve as a termination in a power converter;

obtaining an electrically conductive top plate that is dimensioned to cover said top surface of said at least one solid magnetic core, said base plate being manufactured of a material having sufficient electrical conductivity to allow said base plate to serve as a termination in a power converter;

bonding said bottom surface of said at least one solid magnetic core directly to said conductive base plate;

bonding said conductive top plate directly to said top surface of at least one solid magnetic core;

connecting the at least a first output to said conductive base plate; and

connecting the at least a second output to said conductive top plate;

wherein at least one of said steps of obtaining said conductive base plate and obtaining said conductive top plate further comprises obtaining a conductive plate manufactured of a material that is both electrically conductive and thermally conductive and has at least one surface dimensioned to serve as a heat conductive path to a heat sink; and

wherein said resulting module may utilize said conductive base plate as a first termination and may utilize said conductive top plate as a second termination and may utilize at least one surface of one of said conductive base plate and said conductive top plate as a heat conductive path to a heat sink.

2. The method as claimed in claim 1:

wherein said obtaining step comprises obtaining a solid transformer magnetic core comprising at least a center-tapped secondary winding having a first end, a second end, and a center-tap, and obtaining a solid inductor magnetic core having thereon at least an inductor winding having a first termination and a second termination; and

further comprising the steps of connecting said center-tap of said center-tapped secondary winding to a first termination of the inductor winding, and connecting said second termination of said inductor winding to said conductive top plate.

3. The method as claimed in claim 1 wherein each of said steps of obtaining said conductive base plate and obtaining said conductive top plate further comprise obtaining a conductive plate manufactured of a material that is both electrically and thermally conductive and has at least one surface dimensioned to serve as a heat conductive path to a heat sink.