Header plate for a low profile surface mount transformer

Inductor devices – Winding with terminals – taps – or coil conductor end...

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439 82, H01F 2729

Patent

active

060609745

ABSTRACT:
A transformer is provided that consists of a primary winding, a secondary winding and a magnetic core. The primary winding is wound directly around the magnetic core, thereby removing the need for a bobbin. By removing the need for the bobbin, the transformer has a large window utilization factor, and associated low profile. As a result, the transformer has a high power to form factor ratio. A method for making the transformer includes the steps of joining two halves of the core before winding the primary winding. Because the half-cores are joined prior to the wrapping of the primary winding, the core provides bobbin functionality. In addition, a header plate is provided for coupling a plurality of leads of a transformer to sources on an integrated circuit board, where the transformer consists of a magnetic core, a primary winding and a secondary winding. The header plate engages the magnetic core, providing a termination path for the wire of the secondary winding. In addition, the header plate assists in providing electrical insulation for the core while providing a mechanism for ensuring that electrical safety constraints between the primary winding and the core are satisfied.

REFERENCES:
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patent: 3185948 (1965-05-01), Helberg
patent: 4689023 (1987-08-01), Strong, III et al.
patent: 4745388 (1988-05-01), Billings et al.
patent: 5175525 (1992-12-01), Smith
patent: 5179365 (1993-01-01), Raggi
patent: 5748064 (1998-05-01), Smeenge et al.
Coreless Printed Circuit Board (PCB) Transformers with Multiple Secondary Windings for Complementary Gate Drive Circuits; S.C. Tang, Ron Hui, Henry Chung; May 1999; IEEE Transactions on Power Electronics.

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