Jointless windings for transformers

• US 7,479,863 B2
• Filed: 03/31/2006
• Issued: 01/20/2009
• Est. Priority Date: 03/31/2006
• Status: Active Grant

• Current Assignee: Astec International Limited (Emerson Electric Company)
• Original Assignee: Astec International Limited (Emerson Electric Company)
• Inventors: Hang, Francois Lai Chung, Kit, Checky Chow Chi, Chi, Kelvin So Wing
• Primary Examiner(s): Mai; Anh T
• Application Number:
  US11/396,425
• Publication Number:
  US 20070229206A1
• Time in Patent Office: 1,026 Days
• Field of Search: 336/200, 336/223, 336/232, 296/021, 29605-606
• US Class Current: 336/200
• CPC Class Codes: H01F 2027/2814 with only part of the coil or of the winding in the printed circuit board, e.g. the remaining coil or winding sections can be made of wires or sheets
• CPC Class Codes: H01F 2038/006 matrix transformer consisting of several interconnected individual transformers working as a whole
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A transformer includes at least two windings. Each winding has at least one turn, and the windings are configured from a loop of electrically conductive material.

Claims

1. A transformer comprising:

at least two windings; and

wherein each said winding has at least one turn, the windings are configured from a jointless loop of electrically conductive material.

2. The transformer of claim 1 wherein the transformer comprises a primary winding and a secondary winding, the secondary winding coupled to the primary winding.

3. The transformer of claim 2 wherein the secondary winding is configured from said loop of electrically conductive material.

4. The transformer of claim 3 wherein each said winding includes at least two turns.

5. The transformer of claim 4 wherein the secondary winding has a parallel configuration.

6. The transformer of claim 5 wherein the primary winding comprises a plurality of primary windings.

7. The transformer of claim 6 wherein the plurality of primary windings comprises two primary windings.

8. The transformer of claim 1 wherein the electrically conductive material is copper.

9. The transformer of claim 1 wherein the transformer includes N windings configured from N−

1 jointless loops of electrically conductive material, where N is an integer greater than one.

17. A power converter comprising the matrix transformer of claim 1.

10. A matrix transformer comprising:

a primary winding;

a secondary winding; and

at least one of the windings configured from a single jointless loop of electrically conductive material.

11. The matrix transformer of claim 10 wherein the secondary winding is configured from a single loop of electrically conductive material.

12. The matrix transformer of claim 11 wherein the secondary winding comprises a plurality of windings.

13. The matrix transformer of claim 12 wherein the plurality of windings includes a first winding and a second winding.

14. The matrix transformer of claim 13 wherein the first winding and the second winding each include at least two turns.

15. The matrix transformer of claim 14 wherein the secondary winding has a parallel configuration.

16. The matrix transformer of claim 15 wherein the matrix transformer is a planar transformer and the primary winding is formed on printed a circuit board.

18. A method of making a winding for a matrix transformer, the method comprising:

providing a jointless loop of electrically conductive material; and

folding the loop to form at least two windings for a matrix transformer.

19. The method of claim 18 wherein folding includes at least three folding steps.

20. The method of claim 19 wherein folding includes folding the loop to create at least two windings.

21. The method of claim 20 wherein each of the windings includes at least two turns.

22. The method of claim 21 wherein the secondary winding has a parallel configuration.