Electronic transformer/inductor devices and methods for making same

Abstract

The present invention relates to transformer/inductor devices and to the methods of construction for inductive components such as inductors, chokes, and transformers. Plural via holes are formed through a ferromagnetic substrate. Primary and secondary conductors are placed through common vias to form a plurality of cell transformers have a 1:1 turns ratio. Circuits connect these primary and secondary winding in parallel and serial combustion to provide a transformer having the desired turns ratio.

1 . A method for making a cell core transformer having an efficient flux path with reduced losses comprising: 
 forming a plurality of vias through a substantially planar ferromagnetic material,    forming corresponding vias in a top PCB and a bottom PCB and one or more vias outside said ferromragnetic material;    forming primary conductors through each of said vias extending through said ferromagnetic material;    forming secondary conductors, insulated from said primary conductors, through each of said vias extending through said ferromagnetic material so that each via and the portion of the ferromagnetic material proximate thereto functions as a 1:1 turns ratio transformer;    forming PCB circuits in said top PCB and said bottom PCB to connect said primary and said secondary conductors in parallel or serial circuits determined by the desired turns ratio of the cell core transformer;    forming electrical conductors through one or more of said vias outside said ferromagnetic material to connect circuits on said top and bottom PCB's; and    laminating said planar ferromagnetic material between said top PCB and said bottom PCB.    
   
   
       2 . A method for making a cell core transformer having an efficient flux path with reduced losses comprising: 
 forming a plurality of vias through a substantially planar ferromagnetic material;    forming corresponding vias in flex circuits and one or more vias outside said ferromagnetic material;    forming a primary conductor through each of said vias extending through said ferromagnetic material;    forming secondary conductors, insulated from said primary conductors, through each of said vias extending through said ferromagnetic material so that each via and the portion of the ferromagnetic material proximate thereto functions as a 1:1 turns ratio transformer; and    forming circuits in said flex material to connect said primary and said secondary conductor in parallel or serial circuits determined by the desired turns ratio of the cell core transformer.    
   
   
       3 . A method for making a cell core transformer having an efficient flux path with reduced losses comprising: 
 forming a plurality of vias in spaced rows and columns through a substantially planar ferromagnetic material;    forming primary conductors through at least first and second of said vias in a single row and third and fourth of said vias located in the adjacent row, said third via being located in the same column as said first via and said fourth via being located in the same column as said second via, each of said vias extending through said ferromagnetic material;    forming secondary conductors, insulated from said primary conductors, through at least each of said same respective first, second, third and fourth said vias extending through said ferromagnetic material so that each via and the portion of the ferromagnetic material proximate thereto operates as a 1:1 turning ratio transformer; and    forming circuits to connect said primary conductors together so that the direction of current flow in said first and third vias is opposite to the direction of current flow in said second and fourth vias whereby resulting flux generated between each via has the same orientation; and    forming circuits to connect and said secondary conductors in parallel or serial circuits determined by the desired turns ratio of the cell core transformer.    
   
   
       4 . A method for making a cell core transformer comprising: 
 forming a plurality of via holes in spaced rows and columns through a slab or ferromagnetic material;    forming a plurality of primary conductors respectively extending through said via holes so that current through those conductors creates a plurality of respective magnetic fields within a portion of the ferromagnetic material proximally encompassing said via holes;    forming a plurality of secondary conductors respectively physically extending through the same via holes in which said primary conductors extend;    forming circuits to said primary conductors so that current flowing in any single via will be in the opposite direction from the current flowing in any adjacent via in its same row or column; and    forming circuits to said secondary conductors to provide a desired turn ratio for said cell transformer.    
   
   
       5 . The method of claim  13  wherein said steps of forming circuits includes forming printed circuits on the top and bottom surfaces of the slab respectively in electrical contact with said primary and said secondary conductors.  
   
   
       6 . The method of claim  13  wherein said step of forming circuits to said secondary conductors results in said conductors being connected in series.  
   
   
       7 . The method of claim  13  wherein said step of forming circuits to said secondary conductors results in said conductors being connected in parallel.