Electrical transformer

• US 6,952,153 B2
• Filed: 02/04/2003
• Issued: 10/04/2005
• Est. Priority Date: 02/04/2003
• Status: Expired due to Term

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Chignola, Bruce William, Wesolowski, William Edward, Martin, Kevin Edward, Dakessian, Garo, Kling, Dennis Robert, Praeger, Eberhardt, Jacobson, Boris Solomon
• Primary Examiner(s): Donovan, Lincoln
• Assistant Examiner(s): Poker, Jennifer A.
• Application Number:
  US10/357,595
• Publication Number:
  US 20040150502A1
• Time in Patent Office: 973 Days
• Field of Search: 336/200, 336/223, 336/232, 336/83, 336/65, 336/96, 336/229, 336/205, 296/021
• 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 primary winding segments and secondary winding segments interconnected, respectively, by first and second multilevel printed circuit boards disposed in a pair of overlaying planes and additional segments disposed perpendicular to the overlaying planes.

Claims

1. 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.

2. The electrical transformer recited in claim 1 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.

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 core material comprises a toroidal shaped body and wherein dielectric body is disposed in a central region of the toroidal shaped body.

5. The electrical transformer recited in claim 1 wherein each one of the third conductor segments has a pair of electrically conductive tabs, each one of the tabs extending beyond a corresponding one of a pair of opposing ends of the dielectric body, each one the tabs being electrically connected to a corresponding one of the printed circuit boards.

13. The electrical transformer recited in claim 5 wherein such third conductor segments have electrically conductive surfaces portions, such surface portions being disposed about an outer surface portion of the dielectric body.

14. The electrical transformer recited in claim 5 wherein each one of the third conductor segments has a surface portion having opposing edges, wherein the tabs have width portions projecting from edges of the electrically conductive surfaces, and wherein the edges have lengths longer than the width portions.

6. 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.

7. The electrical transformer recited in claim 6 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.

8. The electrical transformer recited in claim 7 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.

9. The electrical transformer recited in claim 8 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.

10. 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 and having disposed therein portions of 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.

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 including wherein the primary and secondary winding provide loops around the cores.