JP6138540B2 - Transformer and manufacturing method thereof - Google Patents

Description

  The present invention relates to a transformer and a method for manufacturing the transformer.

  In recent years, transformers are used in various electronic devices, and miniaturization of transformers is required to save space for electronic devices. Generally, a transformer includes a primary winding, a secondary winding, and a core portion that magnetically couples the primary winding and the secondary winding. The transformer transformation ratio, that is, the voltage ratio between the primary side voltage and the secondary side voltage is determined by the ratio between the number of turns of the primary winding and the number of turns of the secondary winding.

  Patent Document 1 discloses a technique related to a transformer including a substrate including a conductor pattern constituting a primary winding, a substrate including a conductor pattern constituting a secondary winding, and a core portion disposed around these substrates. Is disclosed. Patent Document 2 discloses a technology related to a reactor that can reduce the number of parts and can have both heat dissipation characteristics and mechanical characteristics.

International Publication No. 2009/131559 JP 2010-93138 A

  In the technique disclosed in Patent Document 1, since the primary winding and the secondary winding are configured using a substrate including a conductor pattern, the transformer can be reduced in size. However, since a high voltage is applied to the transformer, the voltage difference between the primary side terminal (terminal to which the primary winding is connected) and the secondary side terminal (terminal to which the secondary winding is connected) is large. Become. For this reason, when a transformer is configured, it is necessary to ensure a sufficient insulation distance between the primary side terminal and the secondary side terminal in order to prevent a short circuit between the primary side terminal and the secondary side terminal.

  Therefore, even when the technique disclosed in Patent Document 1 is used, it is necessary to secure a sufficient insulation distance between the primary side terminal and the secondary side terminal. It was difficult to do. In other words, it has been difficult to simultaneously realize a reduction in size and a high withstand voltage of the transformer.

  In view of the above problems, an object of the present invention is to provide a transformer having a small size and high withstand voltage characteristics and a method for manufacturing the transformer.

  A transformer according to an aspect of the present invention is provided in a base material made of an insulating material, a primary side conductor layer provided in the base material and electrically connected to a primary side terminal, and the base material. A transformer body having a secondary side conductor layer electrically connected to the secondary side terminal, and the primary side conductor layer and the secondary side conductor layer are laminated to each other via an insulating material. A concave portion and a convex portion are formed on at least a part of the surface of the base material between the primary side terminal and the secondary side terminal.

  According to one aspect of the present invention, there is provided a method of manufacturing a transformer in which a plurality of primary conductor layers, a plurality of insulator substrates, and a plurality of secondary conductor layers are stacked on each other, and concave and convex portions are formed on side surfaces. 1 structure is formed, a plurality of insulator substrates are stacked on each other, a second structure having a side surface and one main surface formed with a recess and a protrusion is formed, and the plurality of insulator substrates are stacked on each other And forming a third structure having a side surface and one main surface formed with a recess and a convex, and forming one main surface of the first structure and the other main surface of the second structure. And the other main surface of the first structure and the other main surface of the third structure are bonded to produce a transformer main body.

  According to the present invention, it is possible to provide a transformer having a small size and high withstand voltage characteristics and a method for manufacturing the transformer.

It is a top view of the transformer concerning an embodiment. It is a side view of the transformer concerning an embodiment. FIG. 3 is a cross-sectional view taken along the cutting line III-III of the transformer shown in FIG. 1. FIG. 4 is a cross-sectional view taken along section line IV-IV of the transformer shown in FIG. 2. FIG. 5 is a cross-sectional view taken along a cutting line VV of the transformer shown in FIG. 2. It is sectional drawing in the cutting | disconnection line VI-VI of the transformer shown in FIG. It is sectional drawing in the cutting | disconnection line VII-VII of the transformer | transformer shown in FIG. It is sectional drawing for demonstrating an example of the connection method of a primary side conductor layer. It is sectional drawing for demonstrating an example of the connection method of a primary side conductor layer. It is sectional drawing for demonstrating an example of the connection method of a primary side conductor layer. It is sectional drawing for demonstrating an example of the connection method of a primary side conductor layer. It is an expanded sectional view showing an example of the uneven part with which the transformer concerning an embodiment is provided. It is an expanded sectional view showing an example of the uneven part with which the transformer concerning an embodiment is provided. It is an expanded sectional view showing an example of the uneven part with which the transformer concerning an embodiment is provided. It is an expanded sectional view showing an example of the uneven part with which the transformer concerning an embodiment is provided. It is an expanded sectional view showing an example of the uneven part with which the transformer concerning an embodiment is provided. It is a side view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a side view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a side view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is sectional drawing for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a top view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a side view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is sectional drawing for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is sectional drawing for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a top view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a top view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a side view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a top view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a side view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a side view for demonstrating the manufacturing method of the trans | transformer concerning embodiment. It is a top view for demonstrating the manufacturing method of the trans | transformer concerning embodiment.

  Embodiments of the present invention will be described below with reference to the drawings. Below, although the transformer provided with a core part is explained, the present invention is applicable also to a transformer not provided with a core part. In other words, the core portion is not necessarily provided as long as the primary side conductor layer and the secondary side conductor layer provided in the transformer main body portion can be magnetically coupled. Generally, the conversion efficiency of the transformer is higher when the core portion is provided. However, for example, when the transformer is driven in a high frequency band, sufficient conversion efficiency may be obtained without providing the core portion.

  FIG. 1 is a top view of the transformer according to the present embodiment. FIG. 2 is a side view of the transformer according to the present embodiment. 3 is a cross-sectional view of the transformer shown in FIG. 1 taken along section line III-III. 4 is a cross-sectional view of the transformer shown in FIG. 2 taken along section line IV-IV. 5 is a cross-sectional view of the transformer shown in FIG. FIG. 6 is a cross-sectional view taken along section line VI-VI of the transformer shown in FIG. FIG. 7 is a cross-sectional view taken along section line VII-VII of the transformer shown in FIG.

  As shown in FIGS. 1 and 2, the transformer 1 according to the present embodiment includes a transformer main body portion 10 and a core portion 12. The transformer main body 10 includes a base material 11, a primary conductor layer 20, and a secondary conductor layer 25 (see FIG. 3).

  The base material 11 is a structure serving as a base material of the transformer main body 10 and can be configured using an insulating material. The base material 11 includes a primary side terminal 17 at an end portion of the primary side 15 of the base material 11. Further, the base material 11 includes a secondary side terminal 18 at the end of the secondary side 16 of the base material 11. For example, the transformer main body 10 has a rectangular shape, and the primary side terminal 17 and the secondary side terminal 18 are arranged at respective end portions in the longitudinal direction of the transformer main body 10. The primary side terminal 17 is a terminal connected to the primary side conductor layer 20. The secondary side terminal 18 is a terminal connected to the secondary side conductor layer 25. The primary side terminal 17 and the secondary side terminal 18 are exposed to the outside of the base material 11 at the ends of the primary side 15 and the secondary side 16 of the base material 11, respectively.

  Further, a convex portion 13 and a concave portion 14 are formed on at least a part of the surface of the base material 11 between the primary side terminal 17 and the secondary side terminal 18. In the example shown in FIGS. 1 and 2, convex portions 13 and concave portions 14 are formed on the side surface and the upper and lower surfaces of the base material 11. In other words, the convex portion 13 and the concave portion 14 are formed on the surface provided between the primary terminal 17 and the secondary terminal 18 among the surfaces of the base material 11.

  As shown in FIGS. 3 and 4, the primary conductor layer 20 (in the cross-sectional view shown in FIG. 4, the primary conductor layer 21 disposed on the uppermost side) is provided in the substrate 11. And is electrically connected to the primary side terminal 17. The primary conductor layer 20 corresponds to the primary winding of the transformer. For example, as shown in FIG. 4, the primary conductor layer 21 extends from the primary terminal 17 toward the secondary side 16, and further goes around the core portion 12 provided in the through hole 19 of the base material 11. To form. At this time, one end of the primary conductor layer 21 is connected to the primary terminal 17_1, and the other end is connected to the primary terminal 17_2. The primary conductor layer 20 can be configured using a metal material such as copper or aluminum, for example.

  Although FIG. 3 shows an example in which the transformer main body 10 includes four primary conductor layers 20, the number of primary conductor layers 20 can be arbitrarily determined. When a plurality of primary conductor layers 20 are provided, the plurality of primary conductor layers 20 can be electrically connected to each other through, for example, through holes. The plurality of primary conductor layers 20 can be electrically connected to each other by, for example, connecting the plurality of primary terminals 17 together.

  8A and 8B are cross-sectional views for explaining a case where a plurality of primary conductor layers 21 and 22 are electrically connected to each other through through holes. The primary side conductor layer 21 shown in FIG. 8A and the primary side conductor layer 22 shown in FIG. 8B are arranged in different layers. As shown in FIG. 8A, one end of the primary conductor layer 21 is connected to the primary terminal 17a, and the other end is connected to the primary terminal 17b. As shown in FIG. 8B, one end of the primary conductor layer 22 is connected to the primary terminal 17b, and the other end is connected to the primary terminal 17c. At this time, the other end of the primary conductor layer 21 and one end of the primary conductor layer 22 are electrically connected to each other using a through hole provided in the primary terminal 17b.

  Therefore, in the primary side conductor layers 21 and 22 shown in FIGS. 8A and 8B, electricity flows in the order of the primary side terminal 17a, the primary side conductor layer 21, the primary side terminal 17b, the primary side conductor layer 22, and the primary side terminal 17c. (When electricity flows from the primary side terminal 17c to the primary side terminal 17a, the order in which electricity flows is reversed). In this case, the primary side conductor layers 21 and 22 are arranged around the core portion 12 so as to make two rounds.

  9A and 9B are cross-sectional views for explaining a case where a plurality of primary side conductor layers 21 and 22 are electrically connected to each other by connecting a plurality of primary side terminals 17 to each other. Also in this case, the primary conductor layer 21 shown in FIG. 9A and the primary conductor layer 22 shown in FIG. 9B are arranged in different layers. As shown in FIG. 9A, one end of the primary conductor layer 21 is connected to the primary terminal 17d, and the other end is connected to the primary terminal 17e. As shown in FIG. 9B, one end of the primary conductor layer 22 is connected to the primary terminal 17f, and the other end is connected to the primary terminal 17g. At this time, the primary side terminal 17e and the primary side terminal 17f are electrically connected using the conductive member 30 to electrically connect the other end of the primary side conductor layer 21 and one end of the primary side conductor layer 22. can do.

  Therefore, the primary side conductor layers 21 and 22 shown in FIG. 9A and FIG. 9B include the primary side terminal 17d, the primary side conductor layer 21, the primary side terminal 17e, the conductive member 30, the primary side terminal 17f, the primary side conductor layer 22, and the primary side conductor layer. It is connected so that electricity flows in the order of the side terminals 17g (when electricity flows from the primary side terminal 17g to the primary side terminal 17d, the order in which electricity flows is reversed). In this case, the primary side conductor layers 21 and 22 are arranged around the core portion 12 so as to make two rounds.

  In addition, although the case where the several primary side conductor layer 20 was mutually connected in series was demonstrated above, you may connect the some primary side conductor layer 20 mutually in parallel. Also in this case, a plurality of primary conductor layers 20 may be connected in parallel to each other through through holes, and a plurality of primary conductor layers 20 are connected to each other by connecting a plurality of primary terminals 17 to each other. You may connect in parallel.

  Each of the plurality of primary conductor layers 20 is connected to one of the primary terminals 17. Therefore, by determining the connection state of a plurality of primary side conductor layers 20 when using a transformer (that is, by determining the number of primary side conductor layers 20 to be used), the number of turns of the primary side conductor layers can be reduced. Can be adjusted. The connection state of the plurality of primary side conductor layers 20 is adjusted by providing a through hole in the primary side terminal 17 or connecting the primary side terminals 17 to each other using the conductive member 30 (see FIGS. 9A and 9B). be able to.

  As shown in FIGS. 3 and 5, the secondary conductor layer 25 (in the cross-sectional view shown in FIG. 5, the uppermost secondary conductor layer 26 is provided) is provided in the substrate 11. And is electrically connected to the secondary terminal 18. The secondary conductor layer 25 corresponds to the secondary winding of the transformer. For example, as shown in FIG. 5, the secondary conductor layer 26 extends from the secondary terminal 18 in the direction of the primary side 15, and further goes around the core portion 12 provided in the through hole 19 of the base material 11. To form. At this time, one end of the secondary conductor layer 26 is connected to the secondary terminal 18_1, and the other end is connected to the secondary terminal 18_2. The secondary conductor layer 25 can be configured using a metal material such as copper or aluminum, for example.

  Although FIG. 3 shows an example in which the transformer body 10 includes four secondary conductor layers 25, the number of layers of the secondary conductor layers 25 can be arbitrarily determined. When a plurality of secondary conductor layers 25 are provided, the plurality of secondary conductor layers 25 can be electrically connected to each other through, for example, through holes. The plurality of secondary conductor layers 25 can be electrically connected to each other by, for example, connecting the plurality of secondary terminals 18 to each other. The method for connecting the plurality of secondary conductor layers 25 is the same as the method for connecting the plurality of primary conductor layers 20 (see FIGS. 8A, B, 9A, and B), and therefore redundant description is omitted. .

  The plurality of secondary conductor layers 25 may be connected in series with each other or may be connected in parallel with each other. The plurality of secondary conductor layers 25 are each connected to one of the secondary terminals 18. Therefore, by determining the connection state of the plurality of secondary conductor layers 25 when using a transformer (that is, by determining the number of secondary conductor layers 25 to be used), The number of turns can be adjusted. As for the connection state of the plurality of secondary side conductor layers 25, a through hole is provided in the secondary side terminal 18, or the secondary side terminals 18 are connected to each other using the conductive member 30 (see FIGS. 9A and 9B). Can be adjusted.

  As shown in FIG. 3, the primary side conductor layer 20 and the secondary side conductor layer 25 are laminated | stacked on each other via the insulating material. In the example shown in FIG. 3, a plurality of primary conductor layers 20 are arranged near the central portion in the stacking direction, and a plurality of secondary conductor layers 25 are arranged on the end sides (upper surface side and lower surface side) in the stacking direction. ing. However, the arrangement of the primary conductor layer 20 and the secondary conductor layer 25 shown in FIG. 3 is an example, and the arrangement of the primary conductor layer 20 and the secondary conductor layer 25 can be arbitrarily determined.

  Moreover, you may comprise the base material 11 using a some insulator board | substrate. In this case, the transformer main body 10 can be configured by laminating a plurality of primary conductor layers 20, a plurality of insulator substrates, and a plurality of secondary conductor layers 25. As the insulator substrate constituting the base material 11, for example, a glass epoxy substrate, a glass composite substrate, a paper epoxy substrate, a bakelite substrate, or the like can be used.

  When the base material 11 is constituted by using a plurality of insulator substrates, it is preferable that the respective insulator substrates constituting the base material 11 are made of the same material. By using the same insulator substrate, resistance to vibration and impact of the base material 11 can be increased. Moreover, by using the same insulator substrate, the thermal expansion coefficient of the insulator substrate which comprises the base material 11 can be made substantially equal, and the temperature cycle characteristic of the base material 11 can be improved.

  The core portion 12 is disposed so as to surround at least a part of the primary conductor layer 20 and at least a part of the secondary conductor layer 25. The core part 12 can be comprised using magnetic materials, such as a ferrite. As shown in FIGS. 1 and 2, the core portion 12 is provided so as to cover the periphery of the transformer main body portion 10 near the secondary side 16. In addition, as shown in FIG. 6, a part of the core portion 12 is inserted through a through hole 19 formed in the base material 11.

  Here, in the transformer according to the present embodiment, the voltage at the primary side terminal 17 is higher than the voltage at the secondary side terminal 18. Therefore, the core part 12 is provided in the secondary side terminal 18 side with a low voltage. In other words, the distance between the end on the primary side terminal 17 side of the core part 12 and the primary side terminal 17 is longer than the distance between the end on the secondary side terminal 18 side of the core part 12 and the secondary side terminal 18. .

  As shown in FIG. 7, the core part 12 can be comprised using the core members 12a and 12b whose cross-sectional shape is E type. And the core part 12 can be attached to the transformer main body part 10 by sandwiching the transformer main body part 10 between the core members 12a and 12b. As shown in FIG. 7, since the primary side conductor layer 20 and the secondary side conductor layer 25 are embedded in the base material 11, they are not in direct contact with the core portion 12, and the insulation is maintained. Moreover, the primary side conductor layer 20 and the secondary side conductor layer 25 can be magnetically coupled by surrounding the primary side conductor layer 20 and the secondary side conductor layer 25 with the core portion 12.

  In the transformer according to the present embodiment, a high voltage is applied to the primary side terminal 17. Here, since the primary side terminal 17 is exposed to the outside of the base material 11, the insulation distance between the primary side terminal 17 and the secondary side terminal 18 (when the core portion 12 is grounded, the primary side terminal It is necessary to ensure an insulation distance between the core 17 and the core portion 12. Therefore, in the transformer according to the present embodiment, the convex portion 13 and the concave portion 14 are formed on at least a part of the surface of the base material 11 between the primary side terminal 17 and the secondary side terminal 18. In the example shown in FIGS. 1 and 2, convex portions 13 and concave portions 14 are formed on the side surface and the upper and lower surfaces of the base material 11.

  Further, in the present embodiment, the voltage of the primary side terminal 17 is higher than the voltage of the secondary side terminal 18, and therefore, the convex portion 13 and the concave portion 14 disposed between the primary side terminal 17 and the core portion 12. The number is larger than the number of the convex part 13 and the recessed part 14 which are arrange | positioned between the secondary side terminal 18 and the core part 12. FIG.

  FIG. 10 is an enlarged cross-sectional view illustrating an example of a concavo-convex portion included in the transformer according to the present embodiment. D <b> 1 shown in FIG. 10 indicates a spatial distance that is an interval between the convex portion 13 a and the convex portion 13 b formed on the surface of the substrate 11. D2 indicates the creepage distance along the side wall and the bottom surface of the recess 14 formed on the surface of the substrate 11. For example, the longer the spatial distance d1, the longer the distance between the convex portion 13a and the convex portion 13b, and the higher the effect of suppressing the discharge between the convex portion 13a and the convex portion 13b. Also, for example, the creepage distance d2 can be increased by forming the recess 14 deeply, and the insulation distance on the surface of the transformer main body 10 can be increased. That is, the insulation distance between the primary side terminal 17 and the secondary side terminal 18 (in the case where the core part 12 is grounded, the insulation distance between the primary side terminal 17 and the core part 12) may be increased. it can. Thereby, the insulation of the transformer main body 10 can be improved.

  In this Embodiment, it is the distance along the side wall and bottom face of the recessed part 14 currently formed in the surface of the base material 11, and the spatial distance d1 which is the space | interval of the convex part 13 formed in the surface of the base material 11. The convex portion 13 and the concave portion 14 are formed so that the creepage distance d2 becomes a predetermined ratio. Here, the ratio (d1 / d2) between the spatial distance d1 and the creepage distance d2 is the voltage applied to the primary terminal 17, the necessary insulation distance, the environment in which the transformer is used (temperature, atmospheric pressure, pollution degree, etc.), etc. Can be determined in consideration of As an example, the ratio (d1 / d2) between the spatial distance d1 and the creepage distance d2 can be about d1 / d2 = 1/3.

  Moreover, it is preferable that the intervals between the convex portions 13 formed on the surface of the substrate 11 are substantially equal. In other words, it is preferable to make the spatial distances d1 of the respective convex portions 13 substantially equal. On the surface of the transformer main body 10, discharge is likely to occur at a portion where the spatial distance d1 is the shortest. For this reason, even if a convex part with a long spatial distance d1 is formed on the surface of the transformer main body part 10, if there is a convex part with a short spatial distance d1, discharge is preferentially generated at that part. Therefore, the convex part with a long spatial distance d1 is wasted, and the space of the transformer main body part 10 cannot be used effectively. For this reason, the space of the transformer main body 10 can be effectively utilized by setting the intervals between the convex portions 13 to be substantially equal.

  Moreover, in this Embodiment, you may make the shape of an uneven | corrugated | grooved part into a shape as shown in FIGS. For example, as shown in FIG. 11, you may comprise so that the bottom face of recessed part 14 'may curve toward the center direction of the transformer main-body part 10. As shown in FIG. By curving the bottom surface of the recess 14 ′, the creepage distance d 2 is increased, and the insulation distance on the surface of the transformer main body 10 can be increased. Further, by bending the bottom surface of the concave portion 14 ′, the mechanical strength of the root portions of the convex portions 13a and 13b can be improved.

  Further, as shown in FIG. 12, the cross-sectional shape (the cross-sectional shape in a plane perpendicular to the stacking direction of the primary side conductor layer 20 and the secondary side conductor layer 25) of the tip portions of the convex portions 13a ′ and 13b ′ is a curved shape 31a. , 31b may be configured. Thus, the mechanical strength of convex part 13a ', 13b' can be improved by making the front-end | tip part of convex part 13a ', 13b' into curved shape 31a, 31b.

  Further, as shown in FIG. 13, the bottom surface of the concave portion 14 ′ may be curved, and the tip portions of the convex portions 13a ′ and 13b ′ may be curved shapes 31a and 31b (combination of FIGS. 11 and 12).

  Further, as shown in FIG. 14, a cross section at the base portion of the two convex portions 13a '' and 13b '' and the bottom surface of the concave portion 14 '' sandwiched between the two convex portions 13a '' and 13b ''. You may comprise so that a shape may become circular arc shape 32. FIG. Thus, by setting the cross-sectional shape of the recess 14 ″ to the arc shape 32, the creepage distance can be increased without deepening the recess 14 ″. For example, when the primary-side conductor layer 20 and the secondary-side conductor layer 25 are disposed up to the vicinity of the side surface of the base material 11, the concave portion formed on the side surface of the base material 11 cannot be deepened. In such a case, the creepage distance can be increased without making the recess 14 ″ deeper by setting the cross-sectional shape of the recess 14 ″ to the arc shape 32.

  In FIGS. 1 and 2, the case where the convex portion 13 and the concave portion 14 are formed on the side surface and the upper and lower surfaces of the base material 11 is shown as an example. It is not necessary to form on all sides. The surface on which the convex portion 13 and the concave portion 14 are formed can be arbitrarily determined according to the arrangement of the primary side terminal and the secondary side terminal and the voltage applied to the primary side terminal and the secondary side terminal. In consideration of the insulation on the surface of the base material 11, it is preferable to form the convex portions 13 and the concave portions 14 on the side surface and the upper and lower surfaces of the base material 11 as shown in FIGS. 1 and 2.

  In the technique disclosed in Patent Document 1, since the primary winding and the secondary winding are configured using a substrate including a conductor pattern, the transformer can be reduced in size. However, since a high voltage is applied to the transformer, the voltage difference between the primary side terminal (terminal to which the primary winding is connected) and the secondary side terminal (terminal to which the secondary winding is connected) is large. Become. For this reason, when a transformer is configured, it is necessary to ensure a sufficient insulation distance between the primary side terminal and the secondary side terminal in order to prevent a short circuit between the primary side terminal and the secondary side terminal.

  Therefore, even when the technique disclosed in Patent Document 1 is used, it is necessary to secure a sufficient insulation distance between the primary side terminal and the secondary side terminal. It was difficult to do. In other words, it has been difficult to simultaneously realize a reduction in size and a high withstand voltage of the transformer.

  Therefore, in the transformer 1 according to the present embodiment, the primary side conductor layer 20 and the secondary side conductor layer 25 are provided in the base material, and the primary side conductor layer 20 and the secondary side conductor layer 25 are laminated to each other via an insulating material. doing. Thus, since the winding which comprises a transformer is comprised using the conductor layer, a transformer can be reduced in size. Furthermore, in the transformer 1 according to the present embodiment, the convex portion 13 and the concave portion 14 are formed on at least a part of the surface of the base material 11 between the primary side terminal 17 and the secondary side terminal 18. Thereby, the insulation distance in the surface of the transformer main-body part 10 can fully be ensured, and the withstand voltage characteristic of a transformer can be improved. Therefore, the transformer 1 according to the present embodiment can simultaneously realize a reduction in size and a higher breakdown voltage of the transformer.

  In general, a transformer used at a high voltage needs to increase the insulation distance between the primary side terminal and the secondary side terminal, so that the lengths of the primary side wiring and the secondary side wiring become long. For this reason, the degree of coupling between the primary side wiring and the secondary side wiring is lowered. That is, the leakage inductance component of the primary side wiring and the secondary side wiring increases. When the leakage inductance component is large as described above, an excessive surge voltage is generated in the switching device when the transformer is driven at a high frequency, and the switching device may be damaged.

  In the transformer according to the present embodiment, since the transformer can be reduced in size, the lengths of the primary side wiring and the secondary side wiring can be shortened. Therefore, the leakage inductance component of the primary side wiring and the secondary side wiring can be reduced, and the transformer can be driven at a high frequency while maintaining the withstand voltage characteristics.

  Further, in a transformer using a core, there is a saturation magnetic flux density unique to the material, and therefore there is an upper limit on the magnetic flux density of the core. Here, the magnetic flux density of the core has a property of becoming lower as the frequency for driving the transformer is higher. Therefore, when the transformer is driven at high frequency, the magnetic flux density of the core can be reduced, and the core can be made smaller. That is, in the transformer according to the present embodiment, it is possible to drive the transformer at high frequency by reducing the size of the transformer while maintaining the withstand voltage characteristics. Furthermore, by driving the transformer at high frequency, the core can be made smaller, and the transformer can be further downsized.

  Moreover, in the transformer 1 according to the present embodiment, the base material 11 may be configured using a plurality of insulator substrates. In this case, since the transformer main body 10 can be configured by laminating a plurality of primary conductor layers 20, a plurality of insulator substrates, and a plurality of secondary conductor layers 25, the transformer further includes It can be downsized. Further, since the transformer body 10 is formed by laminating the respective members, the amount of resin (adhesive) used for manufacturing the transformer can be reduced, and bubbles are generated inside the transformer body 10. This can be suppressed. Therefore, the withstand voltage characteristic can be improved.

  At this time, it is good also considering each insulator board | substrate which comprises the base material 11 as the same material. By using the same insulator substrate, resistance to vibration and impact of the base material 11 can be increased. Moreover, by using the same insulator substrate, the thermal expansion coefficient of the insulator substrate which comprises the base material 11 can be made substantially equal, and the temperature cycle characteristic of the base material 11 can be improved. Further, this can improve the stability and reliability of the transformer.

  With the invention according to the present embodiment described above, a transformer having a small size and high withstand voltage characteristics can be provided.

Next, a method for manufacturing the transformer according to the present embodiment will be described.
15A to 15C are side views for explaining an example of a method for manufacturing a transformer according to the present embodiment. As shown in FIG. 15A, when the transformer main body 10 is manufactured, the first structure body 40, the second structure body 50, and the third structure body 60 are formed. The first structure 40 is a structure disposed at the center of the transformer main body 10, and the second structure 50 is a structure disposed above the transformer main body 10, and the third structure Reference numeral 60 denotes a structure disposed under the transformer main body 10.

  The first structure 40 is produced by laminating a plurality of primary conductor layers, a plurality of insulator substrates, and a plurality of secondary conductor layers, and forming the convex portions 43 and the concave portions 44 on the side surfaces in the longitudinal direction. can do. Further, a through hole 49 is formed at a location where the core portion 12 of the first structure 40 is disposed.

  The second structure 50 is manufactured by stacking a plurality of insulating substrates and forming the convex portion 53 and the concave portion 54 on the side surface in the longitudinal direction and the convex portion 55 and the concave portion 56 on one main surface, respectively. Can do. Further, a through hole 59 is formed at a location where the core portion 12 of the second structure 50 is disposed.

  The third structure 60 is manufactured by stacking a plurality of insulating substrates, forming the convex portion 63 and the concave portion 64 on the side surface in the longitudinal direction, and forming the convex portion 65 and the concave portion 66 on one main surface, respectively. Can do. Further, a through hole 69 is formed at a location where the core portion 12 of the third structure 60 is disposed.

  15A, the one main surface 46 of the first structure 40 and the other main surface 58 of the second structure 50 are bonded together, and the other main surface 47 of the first structure 40 is bonded. And the other main surface 68 of the third structure 60 are bonded together to produce the transformer main body 10. For the bonding of the first to third structures 40, 50, 60, for example, an adhesive member such as a thermosetting resin can be used.

  Thereafter, the transformer body 10 is sandwiched between the core members 12a and 12b as shown in FIG. 15B, whereby the core 12 can be attached to the transformer body 10 as shown in FIG. 15C. At this time, the core portion 12 is arranged in the transformer main body portion 10 so that at least a part of the primary conductor layer and at least a part of the secondary conductor layer are surrounded by the core member 12. 15B and 15C, the convex portions and the concave portions after assembling the transformer main body portion 10 are labeled with the convex portions 13 and the concave portions.

  Next, a method for manufacturing the first structure body 40 will be described in detail with reference to FIGS. 16A to 16C. When producing the first structure 40, first, as shown in FIG. 16A, a plurality of primary conductor layers 21 to 24, a plurality of insulator substrates 41a to 41i, and a plurality of secondary conductor layers 26 to 29 are laminated together. Specifically, the insulator substrate 41a, the insulator substrate 41b with the secondary conductor layers 26 and 27 formed on both surfaces, the insulator substrate 41c, and the insulator substrate with the primary conductor layers 21 and 22 formed on both surfaces 41d, an insulator substrate 41e, an insulator substrate 41f with primary side conductor layers 23, 24 formed on both sides, an insulator substrate 41g, an insulator substrate 41h with secondary side conductor layers 28, 29 formed on both sides, and The first laminated body 41 is formed by preparing each of the insulating substrates 41i, laminating them in this order, and bonding them together.

  When bonding each insulator substrate, for example, an adhesive member such as a thermosetting resin can be used. For example, both surfaces of the insulator substrates 41a, 41c, 41e, 41g, 41i (insulator substrate 41a, Each insulator substrate 41a-41i can be bonded by arranging an adhesive member on one side (41i) and laminating each insulator substrate 41a-41i. As the insulator substrate, for example, a glass epoxy substrate, a glass composite substrate, a paper epoxy substrate, a bakelite substrate, or the like can be used. For the reason described above, it is preferable to use a substrate made of the same material for each insulator substrate.

  Further, when forming the conductor layer on the insulator substrate, for example, the conductor layer may be bonded to the insulator substrate with an adhesive. Further, for example, a conductor layer may be formed on an insulator substrate. In addition, arrangement | positioning of the some primary side conductor layers 21-24 shown in FIG. 16A, the some insulator board | substrates 41a-41i, and the some secondary side conductor layers 26-29 is an example, These arrangement | positioning is a transformer main body. It can be appropriately changed according to the structure of the portion 10. In consideration of insulation between conductor layers, a plurality of insulator substrates may be disposed between conductor layers.

  Moreover, as shown in FIG. 17, the 1st laminated body 41 may be formed by laminating | stacking the insulator board | substrate with which the conductor layer was formed in the single side | surface. That is, the insulator substrate 71a, the insulator substrate 71b with the secondary conductor layer 26 formed on one surface, the insulator substrate 71c with the secondary conductor layer 27 formed on one surface, and the primary conductor layer 21 formed on one surface The insulating substrate 71d, the insulating substrate 71e with the primary conductor layer 22 formed on one side, the insulating substrate 71f with the primary conductor layer 23 formed on one side, and the primary conductor layer 24 formed on one side An insulator substrate 71g, an insulator substrate 71h having a secondary conductor layer 28 formed on one surface, and an insulator substrate 71i having a secondary conductor layer 29 formed on one surface were prepared, and these were laminated in this order. The first laminated body 41 may be formed by adhering to each other.

  Also, a plurality of primary conductor layers 21 to 24, a plurality of insulator substrates 41a to 41i, and a plurality of secondary conductor layers 26 to 29 are prepared separately (that is, a conductor layer is prepared separately from the insulator substrate). The first laminate 41 may be formed by laminating them and bonding them together.

  As shown in FIG. 16B, after forming the first stacked body 41, the convex portions 43 and the concave portions 44 are formed on the side surfaces in the longitudinal direction of the first stacked body 41. Moreover, the through-hole 49 is formed in the location where the core part 12 is arrange | positioned. By such a method, the first structure 40 as shown in the side view of FIG. 16C can be manufactured.

  When forming the convex part 43 and the recessed part 44 in the side surface of the 1st laminated body 41, a cutter and a laser processing machine can be used, for example. Further, when cutting out the plurality of first structures 40 from the first stacked body 41, the protrusions 43 and the recesses 44 are formed on the side surfaces of the first stacked body 41 when cutting out each first structure 40. It may be formed. That is, you may cut out each 1st structure 40, and may form the convex part 43 and the recessed part 44 in the side surface of the 1st laminated body 41 simultaneously.

  Next, a method for manufacturing the second structure 50 will be described in detail with reference to FIGS. 18A to 18D. When the second structure 50 is manufactured, first, as shown in FIG. 18A, the second stacked body 51 is formed by stacking a plurality of insulator substrates 51a to 51c and bonding them together. When bonding each insulator substrate, for example, an adhesive member such as a thermosetting resin can be used. As the insulator substrate, for example, a glass epoxy substrate, a glass composite substrate, a paper epoxy substrate, a bakelite substrate, or the like can be used. For the reason described above, it is preferable to use a substrate made of the same material for each insulator substrate.

  Thereafter, as shown in FIG. 18B, a convex portion 53 and a concave portion 54 are formed on the side surface in the longitudinal direction of the second stacked body 51. Moreover, the through-hole 59 is formed in the location where the core part 12 is arrange | positioned. Further, as shown in FIG. 18C, a convex portion 55 and a concave portion 56 are formed on the upper surface of the second stacked body 51. By such a method, the second structure 50 as shown in the side view of FIG. 18D can be manufactured.

  When forming the convex part 53 and the recessed part 54 in the side surface of the 2nd laminated body 51, a cutter and a laser processing machine can be used, for example. Further, when a plurality of second structures 50 are cut out from the second stacked body 51, the protrusions 53 and the recesses 54 are formed on the side surfaces of the second stacked body 51 when cutting out each second structure 50. It may be formed. Moreover, when forming the convex part 55 and the recessed part 56 in the upper surface of the 2nd laminated body 51, a cutter and a laser processing machine can be used, for example.

  Note that the manufacturing method of the third structure body 60 is the same as the manufacturing method of the second structure body 50, and thus redundant description is omitted.

  The transformer main body 10 can be manufactured by bonding the first to third structures 40, 50, and 60 thus manufactured to each other as shown in FIG. 15A. In the transformer manufacturing method described above, when the transformer main body 10 is manufactured, uneven portions are separately formed on the side surfaces of the first to third structures 40, 50, 60. Therefore, since the structure having the same thickness as that of the transformer main body 10 is formed and the uneven portion is formed on the side surface of the structure, the structure forming the uneven portion can be made thinner. There is an advantage that the processing becomes easier.

  Note that when the first to third structures 40, 50, and 60 are manufactured, an insulating substrate in which convex portions and concave portions are formed in advance on the side surfaces may be used. That is, each of the insulating substrates 41a to 41i (FIG. 16A) used when manufacturing the first structure 40, and the insulating substrates 51a to 51c used when manufacturing the second and third structures 50 and 60, respectively. As each of (FIG. 18A), you may use the insulator board | substrate with which the convex part and the recessed part were previously formed in the side surface. When such an insulator substrate is used, since the uneven portion is formed on the side surface when the insulator substrate is laminated, the step of forming the uneven portion on each stacked body can be omitted.

  Further, when the transformer main body 10 is manufactured, a plurality of primary conductor layers, a plurality of insulator substrates, and a plurality of secondary conductors are prepared without manufacturing the first to third structures 40, 50, 60. The transformer body 10 may be manufactured at a time by laminating layers. In this case, the thickness of the laminated body is the same as the thickness of the transformer main body 10, but when the transformer main body 10 is thin, it is possible to form an uneven portion on the side surface. Therefore, when the thickness of the transformer main body 10 is thin enough to form an uneven portion on the side surface, it is possible to reduce the number of steps when the transformer main body 10 is manufactured by manufacturing the transformer main body 10 at a time. it can.

  Further, even when the transformer main body 10 is thick, the first to third structures 40, 50, and 60 are manufactured by using, for example, an insulating substrate in which uneven portions are formed in advance on the side surfaces. Therefore, the transformer main body 10 can be manufactured at a time. This manufacturing method will be described with reference to FIGS. 19A to 19D.

  First, as shown in FIG. 19A, an insulator substrate having a convex portion 83 and a concave portion 84 formed in advance on the side surface is prepared. At this time, the through-hole 89 may be formed in advance at a location where the core portion 12 of the insulator substrate is disposed. The insulator substrate to be prepared includes an insulator substrate having a conductor layer formed on at least one surface.

  After that, as shown in FIG. 19B, an insulating substrate on which convex portions 83 and concave portions 84 are formed in advance is laminated and bonded together to form a laminated body 81. At this time, convex portions 83 and concave portions 84 are formed on the side surfaces of the laminated body 81. Then, as shown in FIGS. 19C and 19D, the convex portion 85 and the concave portion 86 are formed on the upper surface of the multilayer body 81, and the convex portion 87 and the concave portion 88 are formed on the lower surface of the multilayer body 81. By such a method, the transformer main body 10 can be produced.

  Although the present invention has been described with reference to the above embodiment, the present invention is not limited to the configuration of the above embodiment, and those skilled in the art within the scope of the invention of the claims of the present application claims. It goes without saying that various modifications, modifications, and combinations that can be made are included.

DESCRIPTION OF SYMBOLS 1 Transformer 10 Transformer main-body part 11 Base material 12 Core part 13 Convex part 14 Concave part 15 Primary side 16 Secondary side 17 Primary side terminal 18 Secondary side terminal 19 Through-hole 20, 21, 22, 23, 24 Primary side conductor layer 25 , 26, 27, 28, 29 Secondary conductor layers 31a, 31b Curved shape 40 First structure 41 First laminated body 41a-41i Insulator substrate 43 Convex part 44 Concave part 49 Through hole 50 Second structural body 51 2nd laminated body 51a-51c Insulator board | substrate 53, 55 convex part 54, 56 recessed part 59 through-hole 60 3rd structure 63, 65 convex part 64, 66 recessed part 69 through hole

Claims (20)

A base material made of an insulating material;
A primary conductor layer provided in the base material and electrically connected to the primary terminal;
A transformer body provided with a secondary conductor layer provided in the base material and electrically connected to the secondary terminal;
The primary side conductor layer and the secondary side conductor layer are laminated with each other through an insulating material,
A concave portion and a convex portion are formed on at least a part of the surface of the base material between the primary side terminal and the secondary side terminal ,
The bottom surface of the recess is curved toward the center of the transformer main body,
Trance.   2. The transformer according to claim 1, further comprising a core portion that includes a magnetic material and is disposed so as to surround at least a part of the primary conductor layer and at least a part of the secondary conductor layer, respectively. . The base material includes a plurality of insulator substrates;
A plurality of primary conductor layers, a plurality of insulator substrates, and a plurality of secondary conductor layers are laminated to each other;
The transformer according to claim 1 or 2.   The transformer according to claim 3, wherein each of the insulating substrates constituting the base material is made of the same material.   A predetermined ratio between a spatial distance that is an interval between the convex portions formed on the surface of the base material and a creepage distance that is a distance along the side wall and the bottom surface of the concave portion formed on the surface of the base material The transformer according to claim 1, wherein the concave portion and the convex portion are formed so as to be. The primary side terminal and the secondary side terminal are respectively disposed at respective ends in the longitudinal direction of the transformer main body,
The said recessed part and a convex part are formed in the side surface and upper and lower surface of the said base material which are arrange | positioned between the said primary side terminal and the said secondary side terminal, It is any one of Claims 1 thru | or 5. The described transformer.   The transformer according to any one of claims 1 to 6, wherein the intervals between the convex portions formed on the surface of the substrate are substantially equal intervals.   The transformer according to any one of claims 1 to 7, wherein a cross-sectional shape of a tip portion of the convex portion in a plane perpendicular to a stacking direction of the primary side conductor layer and the secondary side conductor layer is a curved shape. .   The transformer according to any one of claims 1 to 8, wherein a cross-sectional shape of a base portion of the two convex portions and a bottom surface of a concave portion sandwiched between the two convex portions is an arc shape. The voltage of the primary side terminal is higher than the voltage of the secondary side terminal, and the distance between the end on the primary side terminal side of the core part and the primary side terminal is the secondary side of the core part. The transformer according to any one of claims 2 to 9 , wherein the transformer is longer than a distance between an end portion on a side terminal side and the secondary side terminal. The number of concave portions and convex portions arranged between the primary side terminal and the core portion is larger than the number of concave portions and convex portions arranged between the secondary side terminal and the core portion. The transformer according to claim 10 . The transformer according to any one of claims 1 to 11 , wherein the plurality of primary conductor layers are electrically connected to each other through a through hole. The transformer according to any one of claims 1 to 12 , wherein the plurality of primary conductor layers are electrically connected to each other by connecting a plurality of primary terminals. A plurality of primary conductor layers, a plurality of insulator substrates, and a plurality of secondary conductor layers are laminated with each other to form a first structure in which concave portions and convex portions are formed on side surfaces;
A plurality of insulator substrates are laminated together to form a second structure in which a concave portion and a convex portion are formed on a side surface and one main surface,
A plurality of insulator substrates are laminated with each other to form a third structure in which concave portions and convex portions are formed on the side surface and one main surface,
One main surface of the first structure is bonded to the other main surface of the second structure, and the other main surface of the first structure and the other main surface of the third structure are bonded. Bonding the surface to make the transformer body,
Transformer manufacturing method. The transformer manufacturing method according to claim 14 , further comprising: arranging a core portion in the transformer body so as to surround at least a part of the primary conductor layer and at least a part of the secondary conductor layer. When forming the first structure,
A plurality of primary conductor layers, a plurality of insulator substrates, and a plurality of secondary conductor layers are laminated together to form a first laminate;
Forming a recess and a protrusion on a side surface of the first laminate;
The method for producing a transformer according to claim 14 or 15 . When forming the first laminate,
Forming the primary conductor layer on at least one surface of the insulator substrate;
Forming the secondary conductor layer on at least one surface of the insulator substrate;
Laminating the insulator substrate on which the primary conductor layer is formed, the insulator substrate on which the secondary conductor layer is formed, and the insulator substrate;
The method for manufacturing a transformer according to claim 16 . When forming the second and third structures,
Laminating the plurality of insulator substrates together to form second and third laminates,
Forming concave and convex portions on the side surfaces of the second and third laminates, respectively;
Forming a concave portion and a convex portion on one main surface of the second laminate and one main surface of the third laminate, respectively.
The method for manufacturing a transformer according to any one of claims 14 to 17 . When forming the first structure,
Prepare an insulator substrate with concave and convex portions formed on the side,
Laminating the plurality of primary-side conductor layers, the plurality of insulator substrates on which the concave portions and the convex portions are formed, and the plurality of secondary-side conductor layers;
The method for manufacturing a transformer according to claim 14 . When forming the second and third structures,
Prepare an insulator substrate with concave and convex portions formed on the side,
A plurality of insulator substrates formed with the recesses and the protrusions are stacked on each other to form second and third laminates,
Forming a concave portion and a convex portion on one main surface of the second laminate and one main surface of the third laminate, respectively.
The method for manufacturing a transformer according to claim 14 or 19 .

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