Transformer module and power module

Abstract

The application provides a transformer module and a power module. The transformer module comprises a first metal winding, a foil winding on a magnetic core, a first segment winding formed on a first wiring layer and a second segment winding formed on a second wiring layer. A first end of the first segment winding is electrically connected to a first pin through a first connecting piece. A second end of the first segment winding is electrically connected to a second pin through a second connecting piece. The first connecting piece and the second connecting piece both pass through the first insulating layer. A first end of the second segment winding forms a third pin. The first pin and the third pin are both located on a first surface of the transformer module. A second end of the second segment winding forms a fourth pin. The second pin and the fourth pin are both located on a second surface of the transformer module. The loss of the pins is reduced. The transformer module adopts a foil winding structure, so that the winding current is uniformly distributed.

Description

[0001] This application is a divisional application of the invention patent application with the application number 202110657236.2, the application date of October 29, 2019, and the invention name of "Transformer module and power module".

[0002] The invention patent application with the application number 202110657236.2, the application date of October 29, 2019, and the invention name of "Transformer module and power module" enjoys the priority of the invention patent with the application number 201811301174.6, the application date of November 2, 2018, and the invention name of "Transformer module and power module". TECHNICAL FIELD

[0003] The present application relates to the technical field of transformers, in particular to a transformer module and a power module. BACKGROUND

[0004] With the increasing demand for intelligent life, the demand for data processing is growing. The global energy consumption for data processing averages tens of billions or even hundreds of billions of degrees per year; and the land area of a large data center can reach tens of thousands of square meters. Therefore, high efficiency and high power density are key indicators for the healthy development of this industry.

[0005] The key unit of a data center is a server, and the mainboard thereof is usually composed of data processing chips such as a central processing unit (CPU), chipsets, and memories, and their power supplies and necessary peripheral components. With the improvement of the processing capacity of a unit volume server, the number and integration of these processing chips are also improved, resulting in the increase of space occupation and power consumption. Therefore, the power supply for these chips (also known as the mainboard power supply because it is on the same mainboard as the data processing chips) is expected to have higher efficiency, higher power density, and smaller volume to support the energy saving and land area reduction requirements of the entire server and even the entire data center. In order to meet the demand for high power density, the switching frequency of the power supply is also getting higher and higher, and the switching frequency of the low-voltage and high-current power supply in the industry is basically 1 megahertz (MHz).

[0006] For transformers for low-voltage and high-current applications, most of them are implemented in a multi-layer printed circuit board (PCB) manner, FIG. 1 A side view cross-sectional view of a transformer provided by the prior art in a multi-layer PCB manner is shown in FIG. 1. FIG. 1As shown, this type of PCB metal winding uses a horizontal winding process. That is, the winding is formed on a plane (winding layer) on the PCB board, which is typically mounted on magnetic pillars, making the magnetic pillars perpendicular or nearly perpendicular to the PCB board. Therefore, the magnetic pillars are perpendicular or nearly perpendicular to the various winding wiring layers formed on the PCB board. Due to the constraint of forming the winding within the wiring layers, assuming the dimension of the metal winding formed in the wiring layer parallel to the length direction of the magnetic pillar (wiring thickness) is W, and the dimension of the metal winding perpendicular to the length direction of the magnetic pillar (e.g., wiring width) is H, generally, H and W satisfy the following relationship: H > 10W. This type of metal winding is usually called a vertical winding structure metal winding. Even though the various parallel wiring layers are connected by vias, because the main wiring layers are perpendicular to the magnetic pillars, and the vias are perpendicular to the wiring layers, during vertical winding, the vias must be parallel to the magnetic pillars, making it almost impossible for a single via to link magnetic flux. Inner routing layers typically connect to the PCB's surface layer via vias to connect to pins. In vertical winding, the vias are long and few in number, resulting in significant losses. Furthermore, assuming the metal winding in a vertical winding structure forms a loop in the horizontal direction with a loop width of H, it can be seen that in a vertical winding structure, the impedance of the outer portion farther from the magnetic post and the inner portion closer to the magnetic post will differ due to factors such as the inconsistent circumference lengths of the inner and outer loops, leading to uneven current distribution.

[0007] FIG. 2 This is a schematic diagram of another transformer module provided by the prior art. For ease of explanation, the shape of the windings and the positional relationship between the windings and the magnetic core are specifically depicted in the schematic diagram, but this application is not limited thereto. FIG. 2 As shown, in any wiring layer, a winding is formed covering the magnetic core. Different parts of the same turn winding are approximately equidistant from the magnetic core, meaning their equivalent diameters and equivalent impedances are similar, resulting in a uniform current distribution in the winding. If multiple wiring layers are required, an insulating layer and a new wiring layer can be added sequentially outside the existing wiring layers. (Combined with...) FIG. 2 Let W be the dimension of the winding formed in the wiring layer parallel to the length of the magnetic core, and H be the dimension of the winding perpendicular to the magnetic core. When H and W satisfy the relationship W > 10H, we define this winding method as a foil-wound structure winding. In transformers with this structure, the pins connecting each winding to the external circuit, as shown in Figures 21 and 22, are usually led out from the side of the winding. Thus, all the current in the winding flows through this pin, which not only results in uneven current distribution in the winding but also causes significant losses on this pin. Furthermore, in existing transformer structures, this pin is usually quite long, further exacerbating the losses on the pin. Summary of the Invention

[0008] The application provides a transformer module and a power module, so as to realize the purpose of uniform winding distribution and reduce the loss of pins.

[0009] In a first aspect, the application provides a transformer module, comprising:

[0010] a magnetic core, wherein a first wiring layer, a first insulating layer and a second wiring layer are sequentially arranged on the magnetic core from outside to inside;

[0011] a first metal winding formed on the first wiring layer and wrapped around the magnetic core;

[0012] the first insulating layer is at least partially covered by the first metal winding;

[0013] a second metal winding formed on the second wiring layer and wrapped around the magnetic core, wherein the second metal winding is at least partially covered by the first insulating layer and at least partially covered by the first metal winding;

[0014] The transformer module further comprises a first pin, a second pin, a third pin and a fourth pin, the first metal winding comprises a first end and a second end, the second metal winding comprises a first end and a second end, the first end and the second end of the first metal winding form the first pin and the second pin respectively, and the first end and the second end of the second metal winding are electrically connected to the third pin and the fourth pin through a first connecting member and a second connecting member respectively, and the first connecting member and the second connecting member both pass through the first insulating layer.

[0015] Optionally, the first connecting member and the second connecting member also pass through the first wiring layer.

[0016] Optionally, the first connecting member and the second connecting member are vias.

[0017] Optionally, the second metal winding, the first connecting member, the second connecting member, the third pin and the fourth pin are an integral piece.

[0018] Optionally, the first connecting member and the second connecting member are cut from the second metal winding, and the third pin and the fourth pin are folded to form through the first connecting member and the second connecting member respectively.

[0019] Optionally, the first pin, the second pin, the third pin and the fourth pin are located on the first surface of the transformer module for connecting with external circuits.

[0020] Optionally, a second insulating layer and a third wiring layer are sequentially arranged on the magnetic core, and the second insulating layer is at least partially covered by the second metal winding.

[0021] The transformer module further comprises:

[0022] a third metal winding formed on the third wiring layer and wound around the magnetic core, wherein the third metal winding is at least partially covered by the second insulating layer; and

[0023] a fifth pin;

[0024] wherein the third metal winding comprises a first end and a second end, the first end of the third metal winding is electrically connected with the fifth pin through a third connecting member, and the second end of the third metal winding is electrically connected with the first pin.

[0025] Optionally, the third connecting member is a via or is formed by cutting the third metal winding.

[0026] Optionally, the first metal winding has one turn, the second metal winding has multiple turns to form a spiral winding around the magnetic core, and the third metal winding has one turn.

[0027] Optionally, the fifth pin is multiple, and the multiple fifth pins are all located between the first pin and the second pin.

[0028] Optionally, the second pin further comprises multiple teeth, and the multiple teeth are arranged alternately with the multiple fifth pins.

[0029] Optionally, the fifth pin is one, and the fifth pin is located between the first pin and the second pin.

[0030] Optionally, the magnetic core comprises a through hole, wherein on the first surface, the fifth pin is a C-shaped or a mouth-shaped around the through hole, the first pin is a C-shaped or a mouth-shaped around the through hole, and the second pin is a C-shaped or a mouth-shaped around the through hole.

[0031] Optionally, the length of the first pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the length of the second pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the length of the third pin is greater than or equal to 1 / 2 of the length of the second metal winding; and / or, the length of the fourth pin is greater than or equal to 1 / 2 of the length of the second metal winding; and / or, the length of the fifth pin is greater than or equal to 1 / 2 of the length of the third metal winding.

[0032] Optionally, the first pin is multiple, and the total length of the multiple first pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or,

[0033] the second pin is multiple, and the total length of the multiple second pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or,

[0034] the third pin is multiple, and the total length of the multiple third pins is greater than or equal to 1 / 2 of the length of the second metal winding; and / or,

[0035] The fourth pins are multiple, and the total length of the multiple fourth pins is greater than or equal to 1 / 2 of the length of the second metal winding.

[0036] Optionally, the first insulating layer comprises a base insulating layer and an auxiliary insulating layer.

[0037] Optionally, the base insulating layer is formed by an electroplating process, and the auxiliary insulating layer is a locally arranged insulating glue.

[0038] In a second aspect, the application provides a power module, comprising:

[0039] A transformer module as in the first aspect;

[0040] A switch module, the switch module and the first surface of the transformer module are in contact and electrically connected with the first pin and the second pin.

[0041] Optionally, the switch module comprises a carrier plate and at least one power switch, the power switch is arranged on the carrier plate, and the power switch is electrically connected with the first pin and / or the second pin.

[0042] Optionally, the power module further comprises a capacitor module, the capacitor module is arranged on the carrier plate and adjacent to the transformer module, and the capacitor module is electrically connected with the first pin. Alternatively, the capacitor module is arranged on the carrier plate and adjacent to the switch module on the same side; alternatively, the capacitor module is embedded in the carrier plate; alternatively, the capacitor module is arranged in a window of the transformer module; alternatively, the capacitor module is arranged on an upper surface of the magnetic core of the transformer module; or alternatively, the capacitor module is arranged below the power switch.

[0043] Optionally, the magnetic core of the transformer module further comprises a second insulating layer and a third wiring layer arranged in sequence, and the second insulating layer is at least partially covered by the second metal winding.

[0044] The transformer module further comprises:

[0045] A third metal winding formed in the third wiring layer and wound around the magnetic core, wherein the third metal winding is at least partially covered by the second insulating layer; and

[0046] A fifth pin, the fifth pin is located on the first surface of the transformer module.

[0047] The third metal winding comprises a first end and a second end, the first end of the third metal winding is electrically connected with the fifth pin through a third connecting member, and the second end of the third metal winding is electrically connected with the first pin.

[0048] The switch module is further electrically connected with the fifth pin.

[0049] Optionally, the power module further comprises a first power switch and a second power switch, wherein a first end of the first power switch is electrically connected to the second pin, a first end of the second power switch is electrically connected to the fifth pin, and a second end of the first power switch is electrically connected to a second end of the second power switch.

[0050] Optionally, the switch module comprises a plurality of first power switches connected in parallel and a plurality of second power switches connected in parallel, the plurality of first power switches and the plurality of second power switches are arranged in two separate rows, wherein a first end of the plurality of first power switches is electrically connected to the second pin, a first end of the plurality of second power switches is electrically connected to the fifth pin, and a second end of the plurality of first power switches is electrically connected to a second end of the plurality of second power switches.

[0051] In a third aspect, the present application provides a transformer module, comprising:

[0052] a magnetic core, wherein a first wiring layer, a first insulating layer and a second wiring layer are sequentially arranged on the magnetic core from inside to outside;

[0053] a first metal winding, foil-wound on the magnetic core, comprising a first segment winding formed on the first wiring layer and a second segment winding formed on the second wiring layer, a first end of the first segment winding is electrically connected to the first pin through a first connecting piece, a second end of the first segment winding is electrically connected to the second pin through a second connecting piece, the first connecting piece and the second connecting piece both pass through the first insulating layer, a first end of the second segment winding forms the third pin, the first pin and the third pin are both located on a first face of the transformer module, a second end of the second segment winding forms the fourth pin, the second pin and the fourth pin are both located on a second face of the transformer module;

[0054] a second metal winding, foil-wound on the magnetic core, comprising a third segment winding formed on the first wiring layer and a fourth segment winding formed on the second wiring layer, a first end of the third segment winding is electrically connected to the fifth pin through a third connecting piece, a second end of the third segment winding is electrically connected to the second pin through a fourth connecting piece, the third connecting piece and the fourth connecting piece both pass through the first insulating layer, a first end of the fourth segment winding forms the sixth pin, a second end of the fourth segment winding is electrically connected to the fourth pin, the fifth pin and the sixth pin are both located on the same face of the transformer module.

[0055] Optionally, at least one of the first connecting piece, the second connecting piece, the third connecting piece and the fourth connecting piece is a via hole or the metal winding connected with the connecting piece is an integral piece formed by cutting and folding the metal winding.

[0056] Optionally, a third wiring layer and a second insulating layer are further arranged on the magnetic core, wherein the third wiring layer and the second insulating layer are sequentially arranged between the first insulating layer and the second wiring layer; and

[0057] The second metal winding is wound on the magnetic core and is located on the third wiring layer.

[0058] Optionally, the number of turns of the first metal winding is one, the number of turns of the third metal winding is a plurality to form a spiral winding around the magnetic core, and the number of turns of the second metal winding is one.

[0059] Optionally, the first pin is a plurality, the fifth pin is a plurality, and the plurality of first pins and the plurality of fifth pins are arranged alternately, and the plurality of first pins and the plurality of fifth pins are located between the third pin and the sixth pin.

[0060] Optionally, on the first surface, the first pin is in a C shape or a mouth shape, the fifth pin is in a C shape or a mouth shape, and the first pin and the fifth pin are located between the C-shaped or mouth-shaped third pin and the C-shaped or mouth-shaped sixth pin.

[0061] Optionally, on the second surface, the second pin is surrounded by the fourth pin.

[0062] Optionally, the first surface and the second surface of the transformer module are opposite surfaces.

[0063] Optionally, the length of the first pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the length of the second pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the length of the third pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the length of the fourth pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the length of the fifth pin is greater than or equal to 1 / 2 of the length of the second metal winding; and / or, the length of the sixth pin is greater than or equal to 1 / 2 of the length of the second metal winding.

[0064] Optionally, the first pin is a plurality, and the total length of the plurality of first pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or,

[0065] The second pin is a plurality, and the total length of the plurality of second pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or,

[0066] The third pin is a plurality, and the total length of the plurality of third pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or,

[0067] The fourth pin is a plurality, and the total length of the plurality of fourth pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or,

[0068] The fifth pin is a plurality, and the total length of the plurality of fifth pins is greater than or equal to 1 / 2 of the length of the second metal winding; and / or,

[0069] The sixth pins are multiple, and the total length of the multiple sixth pins is greater than or equal to 1 / 2 of the length of the second metal winding.

[0070] Optionally, the first insulating layer comprises a base insulating layer and an auxiliary insulating layer.

[0071] Optionally, the base insulating layer is insulated by an electroplating process, and the auxiliary insulating layer is a locally arranged insulating glue.

[0072] In a fourth aspect, the present application provides a power module, comprising:

[0073] A transformer module as in the third aspect;

[0074] A switch module, the switch module and the first surface of the transformer module are in contact.

[0075] Optionally, the power module further comprises:

[0076] A capacitor module, the capacitor module and the second surface of the transformer module are in contact and electrically connected to the second pin and the fourth pin.

[0077] Optionally, the switch module is electrically connected to the first pin, the third pin, the fifth pin and the sixth pin.

[0078] Optionally, the switch module comprises a plurality of first power switches and a plurality of second power switches, and the plurality of first power switches and the plurality of second power switches are arranged in two separate rows.

[0079] Optionally, the switch module comprises a plurality of first power switches and a plurality of second power switches, and the plurality of first power switches and the plurality of second power switches are arranged on the first surface of the transformer module, the plurality of first power switches are electrically connected to the first pin and the third pin, and the plurality of second power switches are electrically connected to the fifth pin and the sixth pin.

[0080] In a fifth aspect, the present application provides a transformer module, comprising:

[0081] A magnetic core, the magnetic core is sequentially provided with a first wiring layer, a first insulating layer and a second wiring layer from inside to outside;

[0082] A first metal winding, the foil is wound around the magnetic core, and the first metal winding comprises a first segment winding formed on the first wiring layer and a second segment winding formed on the second wiring layer, a first end of the first segment winding is electrically connected to a first end of the second segment winding through a first connecting piece, a second end of the first segment winding is electrically connected to the first pin through a second connecting piece, and a second end of the second segment winding is connected to the second pin, and the first connecting piece and the second connecting piece both pass through the first insulating layer;

[0083] The second metal winding is foil-wound on the magnetic core, and comprises a third segment winding formed on the first wiring layer and a fourth segment winding formed on the second wiring layer, a first end of the third segment winding is connected to a first end of the fourth segment winding through a third connecting member, and a second end of the fourth segment winding forms a third pin, and the third connecting member passes through the first insulating layer.

[0084] Optionally, at least one of the first connecting member, the second connecting member, the third connecting member and the fourth connecting member is a via hole or is integral with the metal winding to which the connecting member is connected and is formed by cutting and folding the metal winding.

[0085] Optionally, the second end of the third segment winding is electrically connected to the first pin, and the transformer module further comprises a third metal winding.

[0086] Optionally, the first pin, the second pin and the third pin are all located on the first face of the transformer module.

[0087] Optionally, a second insulating layer and a third wiring layer are further arranged on the magnetic core, wherein the third wiring layer is sequentially arranged between the first insulating layer and the second wiring layer; and

[0088] The third metal winding is foil-wound on the magnetic core and is located on the third wiring layer.

[0089] Optionally, the third pin is a plurality of third pins, and the second pin further comprises a plurality of tooth-shaped portions, and the plurality of tooth-shaped portions and the plurality of third pins are arranged alternately.

[0090] Optionally, the second pin and the third pin are both a plurality of pins, and the plurality of second pins and the plurality of third pins are arranged alternately.

[0091] Optionally, the magnetic core comprises a through hole, and the first pin, the second pin and the third pin are all C-shaped or mouth-shaped around the through hole, and the first pin is located between the second pin and the third pin.

[0092] Optionally, the magnetic core comprises a through hole, and the first pin, the second pin and the third pin are all a plurality of pins, wherein the plurality of first pins, the plurality of second pins and the plurality of third pins are all arranged around the through hole, and the plurality of first pins are located between the plurality of second pins and the plurality of third pins.

[0093] Optionally, the length of the first pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or the length of the second pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or the length of the third pin is greater than or equal to 1 / 2 of the length of the first metal winding.

[0094] Optionally, the first pin is a plurality of first pins, and the total length of the plurality of first pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or

[0095] the second pins are a plurality of pins, and the total length of the plurality of second pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or,

[0096] the third pins are a plurality of pins, and the total length of the plurality of third pins is greater than or equal to 1 / 2 of the length of the first metal winding

[0097] Optionally, the first insulating layer comprises a base insulating layer and an auxiliary insulating layer.

[0098] Optionally, the base insulating layer is insulated by an electroplating process, and the auxiliary insulating layer is a locally arranged insulating glue.

[0099] In a sixth aspect, the present application provides a power module, comprising:

[0100] A transformer module of the fifth aspect, wherein the first pins, the second pins, and the third pins are all located on the first surface of the transformer module.

[0101] A switch module, the switch module being in contact with the first surface of the transformer module.

[0102] Optionally, the switch module comprises a carrier plate and at least one power switch, the power switch being arranged on the carrier plate, and the power switch being electrically connected with the first pins and / or the second pins.

[0103] Optionally, the power module further comprises:

[0104] A capacitor module, the capacitor module being arranged on the carrier plate and adjacent to the transformer module, and the capacitor module being electrically connected with the first pins or the second pins; or the capacitor module being arranged on the carrier plate and adjacent to the switch module on the same side; or the capacitor module being embedded in the carrier plate; or the capacitor module being located in a window of the transformer module; or the capacitor module being located on the upper surface of the transformer module; or the capacitor module being located below the power switch.

[0105] Optionally, the switch module comprises a plurality of first power switches connected in parallel and a plurality of second power switches connected in parallel, and the plurality of first power switches and the plurality of second power switches are arranged in two separate rows.

[0106] In a seventh aspect, the present application further provides a manufacturing method of a metal winding in a transformer module, comprising: cutting a first metal foil to form a connecting piece and pins; insulating the surface of at least one of the first metal foil and a second metal foil; bending the first metal foil to form a first metal winding, which is wrapped on a magnetic core; wrapping the second metal foil at least partially on the surface of the first metal winding to form a second metal winding, and the pins of the first metal winding penetrating through the second metal winding.

[0107] Optionally, the surface of at least one of the first metal foil and the second metal foil is insulated, including: performing a first insulation treatment on the surface of the metal foil to form a base insulation layer on the inner side; and performing a second insulation treatment on the surface of the metal foil with the base insulation layer to form an auxiliary insulation layer on the outer side.

[0108] Optionally, the base insulation layer is formed by an electroplating process.

[0109] Optionally, the auxiliary insulation layer is a locally-applied insulating glue.

[0110] Optionally, before the surface of at least one of the first metal foil and the second metal foil is insulated, the surface of the at least one metal foil is roughened.

[0111] Optionally, after the surface of at least one of the first metal foil and the second metal foil is insulated, the surface of the at least one metal foil is coated with an adhesive layer.

[0112] Optionally, the second metal winding is wound around the surface of the first metal winding, and a via hole or a gap is formed during the winding to allow the pin of the first metal winding to pass through.

[0113] Optionally, a third metal foil is cut to form a via hole or a gap, the third metal foil is bent and wrapped around the surface of the second metal winding to form a third metal winding, and the pin of the first metal winding passes through the via hole or the gap.

[0114] The present application provides a transformer module and a power module, wherein the transformer module comprises a magnetic core, a first metal winding and a second metal winding. The magnetic core sequentially forms a first wiring layer, a first insulation layer and a second wiring layer from the outside to the inside; the first metal winding is formed on the first wiring layer and is foil-wound on the magnetic core; the first insulation layer is at least partially covered by the first metal winding; the second metal winding is formed on the second wiring layer and is foil-wound on the magnetic core, wherein the second metal winding is at least partially covered by the first insulation layer and is at least partially covered by the first metal winding; the transformer module further comprises a first pin, a second pin, a third pin and a fourth pin; the first metal winding comprises a first end and a second end; the second metal winding comprises a first end and a second end; the first pin, the second pin, the third pin and the fourth pin are all located on the first face of the transformer module for connection with an external circuit; the first end and the second end of the first metal winding form the first pin and the second pin, respectively; the first end and the second end of the second metal winding are electrically connected to the third pin and the fourth pin through a first connecting member and a second connecting member, respectively; and the first connecting member and the second connecting member both pass through the first insulation layer.

[0115] The foil winding structure is wrapped on the transformer magnetic column, so that the equivalent diameter of the foil winding structure is similar, the equivalent impedance is similar, and the winding current distribution is uniform. In addition, the loss of the pin can be reduced by the setting mode of the pin. BRIEF DESCRIPTION OF DRAWINGS

[0116] FIG. 1 A transformer side view sectional view provided by the prior art adopts a multi-layer PCB mode;

[0117] FIG. 2 Another structure diagram of a transformer module provided by the prior art;

[0118] FIG. 3A A perspective view of a magnetic core in a transformer module provided by an embodiment of the present application;

[0119] FIG. 3B A perspective view of the magnetic core shown in FIG. 3A after a second metal winding is formed;

[0120] FIG. 3C A perspective view of the module shown in FIG. 3B after a first metal winding is formed;

[0121] FIG. 3D A perspective view of a transformer module provided by an embodiment of the present application;

[0122] FIG. 3E An electrical schematic diagram of each end point of the transformer module shown in FIG. 3C ;

[0123] FIG. 3F A winding edge perspective view containing two integral pins; FIG. 3C

[0124] A schematic diagram of the relationship between the ratio n of the pin size and the winding size and the winding loss P; FIG. 3G

[0125] A winding edge perspective view containing a plurality of pins; FIG. 3H FIG. 3C A bottom view of the transformer module after a third metal winding is formed;

[0126] FIG. 4A A bottom view of a transformer module provided by an embodiment of the present application;

[0127] FIG. 4B An electrical schematic diagram of each end point of the transformer module shown in

[0128] ; FIG. 4C FIG. 4B

[0129] ​​FIG. 5 A bottom view of another transformer module provided in an embodiment of this application;

[0130] FIG. 6A and FIG. 6B These are electrical schematic diagrams of each terminal of a power module provided in an embodiment of this application;

[0131] FIG. 6C and FIG. 6D These are cross-sectional views of a power module provided in an embodiment of this application;

[0132] FIG. 6E A bottom view of a switch module provided in an embodiment of this application;

[0133] FIG. 6F A cross-sectional view of a power module provided in one embodiment of this application;

[0134] FIG. 7 An electrical schematic diagram of each terminal of a power module provided in an embodiment of this application;

[0135] FIG. 8 For one embodiment of this application, the transformer module is along FIG. 5 The cross-sectional view of line AA' shown;

[0136] FIG. 9A This is a cross-sectional view of the transformer winding in one embodiment of this application;

[0137] FIG. 9B This is a cross-sectional view of the transformer winding in one embodiment of this application;

[0138] FIG. 9C This is a bottom view of a transformer in one embodiment of this application;

[0139] FIG. 9D This is a bottom view of a transformer in one embodiment of this application;

[0140] FIG. 9E As shown FIG. 9C A schematic diagram showing a portion of a transformer and the switching components placed on it, outlined in a dashed box.

[0141] FIG. 9F This is a cross-sectional view of a power module in one embodiment of this application;

[0142] FIG. 10A This is a cross-sectional view of a transformer according to one embodiment of this application;

[0143] FIG. 10B This is a plan view of the winding after unfolding in one embodiment of this application;

[0144] FIG. 10C This is a perspective view of the winding in one embodiment of this application;

[0145] FIG. 10D A perspective view of a winding in an embodiment of the application;

[0146] FIG. 10E A perspective view of a winding in an embodiment of the application;

[0147] FIG. 10F A perspective view of a winding in an embodiment of the application;

[0148] FIG. 10G A schematic diagram of the arrangement of pins in an embodiment of the application;

[0149] FIG. 10B-1 A schematic diagram of the cross-section of a metal layer and an insulating layer;

[0150] FIG. 10B-2 A schematic diagram of the cross-section of a metal layer before it is bent;

[0151] FIG. 10B-3 A schematic diagram of the cross-section of a metal layer after it is bent;

[0152] FIG. 10B-4 A manufacturing process for a metal winding;

[0153] FIG. 11A and FIG. 11B are respectively a schematic diagram of the structure of a transformer module provided in an embodiment of the application;

[0154] FIG. 12A is a cross-sectional view of a transformer module provided in an embodiment of the application along the AB line cross-section shown in FIG. 11A ;

[0155] FIG. 12B is a cross-sectional view of a transformer module provided in an embodiment of the application along the AB line cross-section shown in FIG. 11B ;

[0156] FIG. 13A is a top view of a transformer module provided in an embodiment of the application;

[0157] FIG. 13B is a top view of a transformer module provided in another embodiment of the application;

[0158] FIG. 14A is a bottom view of a transformer module provided in an embodiment of the application;

[0159] FIG. 14B is a bottom view of a transformer module provided in another embodiment of the application;

[0160] FIG. 15 is a cross-sectional view of a power module provided in another embodiment of the application;

[0161] FIG. 16 A top view of a power module provided in another embodiment of this application. Detailed Implementation

[0162] For transformers used in low-voltage, high-current applications, existing technologies mostly employ a vertical winding structure implemented using multi-layer PCBs. In this case, the plane of the PCB is perpendicular to the magnetic core, and the winding is formed around the magnetic core by routing traces on the PCB wiring layers. However, the vertical winding structure leads to an inconsistency in the equivalent diameter of the inner and outer sides of the metal winding traces, resulting in a smaller equivalent impedance on the inner side of the winding compared to the outer side. This causes uneven current distribution in the winding, leading to higher winding losses.

[0163] In addition, another structure in the prior art employs a winding foil structure, in which the distance between the winding and the magnetic core is approximately equal, such as... FIG. 2 As shown, the radius R of each part of the winding. 1B ,R 2B The current distribution across the windings is more uniform compared to transformers with PCB structures, as the current is essentially equal to that of the PCB structure. However, in this structure, the winding outputs are typically led out from the side of the winding, resulting in uneven current distribution near the outputs, especially when the winding width W is wide. Furthermore, the outputs are usually longer, leading to greater losses at the outputs. To address these technical problems, this application provides a transformer module and a power module.

[0164] In one embodiment of the present invention, the winding is formed in the wiring layer by means of electroplating, chemical plating, spraying, immersion, electrophoresis, electrostatic spraying, chemical vapor deposition, physical vapor deposition, evaporation, or printing. Multiple wiring layers can be disposed on the surface of the magnetic component, with insulating layers between the wiring layers. The windings between different wiring layers can be connected by connectors passing through the insulating layers, such as vias.

[0165] Example 1

[0166] FIG. 3A This is a perspective view of a magnetic core in a transformer module according to an embodiment of this application. FIG. 3B In order to be in FIG. 3A The image shown is a 3D view of the magnetic core after the second metal winding has been formed. FIG. 3C In order to be in FIG. 3B The diagram shown is a 3D view (bottom side up) of the module after it has formed the first metal winding. FIG. 3D This is a perspective view of a transformer module provided in one embodiment of this application. FIG. 3E for FIG. 3D The diagram shows the electrical schematics of each endpoint (e.g., pins) of the transformer module, combined with... FIG. 3A to FIG. 3EAs shown, the transformer module comprises a magnetic core 31, a first metal winding 33 (e.g. as the secondary winding S2 of the transformer module, as shown) and a second metal winding 32 (e.g. as the primary winding P of the transformer module, as shown). FIG. 3E FIG. 3E

[0167] Optionally, the magnetic core is a square core, a ring core, an I-shaped core or a C-shaped core. For example, as shown, the magnetic core 31 is a square core. The shape of the magnetic core is not limited in the present application. FIG. 3A

[0168] Optionally, the number of turns of the first metal winding (secondary winding S2) is one or more. For example, as shown, the number of turns of the first metal winding 33 is one. FIG. 3C

[0169] Optionally, the number of turns of the second metal winding (primary winding P) is one or more. As shown, the number of turns of the second metal winding 32 is more, to form a spiral winding around the magnetic columns of the square core. In FIG. 3B, the black thick lines are the exposed insulation layers between the turns of the metal winding. FIG. 3B

[0170] Specifically, the first wiring layer, the first insulation layer and the second wiring layer are sequentially arranged on the magnetic core from outside to inside. As shown, the metal of the second wiring layer can be formed into the second metal winding 32 by etching or other methods, so that the second metal winding 32 is wrapped around the magnetic core 31. After the second metal winding 32 is formed and wrapped around the magnetic core 31, the first insulation layer can be arranged outside the second wiring layer, and the first wiring layer is arranged outside the first insulation layer. Therefore, the second metal winding is at least partially covered by the first insulation layer, and at least partially covered by the first wiring layer. As shown, the first metal winding 33 can be formed on the first wiring layer, and the first metal winding 33 is wrapped around the magnetic core 31. The first metal winding 33 also wraps the second metal winding 32. Therefore, the second metal winding is at least partially covered by the first metal winding, and the first insulation layer is at least partially covered by the first metal winding. The coverage mentioned in the present application can be contact coverage or non-contact coverage (e.g. projection coverage). As mentioned above, the coverage in “the first insulation layer is at least partially covered by the first metal winding” refers to contact coverage. The coverage in “the second metal winding is at least partially covered by the first insulation layer” also refers to contact coverage. The coverage in “the second metal winding is at least partially covered by the first metal winding” refers to non-contact coverage, i.e. projection coverage. FIG. 3B FIG. 3C

[0171] ​​​​​​​Specifically, in an embodiment, an initial insulating layer can be selectively attached to the surface of the magnetic core by spraying or deposition, etc. The initial insulating layer has the functions of enhancing the bonding force and protecting the magnetic core, but the application is not limited thereto, and the initial insulating layer can also not be provided. Then, a second wiring layer can be provided on the surface by electroplating or chemical plating, etc. The second wiring layer can be a copper layer. Then, a metal protective layer, such as a tin layer or a gold layer, etc. can be electroplated or chemically plated on the surface of the second wiring layer. Then, the metal protective layer is pattern defined by a direct writing protection process, exposing the part of the second wiring layer that needs to be etched. Then, the etching of the pattern of the second wiring layer is performed under the protection of the metal protective layer. Finally, the protective layer is removed, forming the second metal winding, which is the primary winding P. Then, a first insulating layer is selectively attached to the second metal winding by spraying or deposition, etc. The first insulating layer has the functions of enhancing the bonding force and protecting the magnetic core. Then, a first wiring layer can be provided on the surface by electroplating or chemical plating, etc. The first wiring layer can be a copper layer. Then, a metal protective layer, such as a tin layer or a gold layer, etc. can be electroplated or chemically plated on the surface of the first wiring layer. Then, the metal protective layer is pattern defined by a direct writing protection process, exposing the part of the first wiring layer that needs to be etched. Then, the etching of the pattern of the first wiring layer is performed under the protection of the metal protective layer. Finally, the protective layer is removed, forming the first metal winding, which is the secondary winding S2. However, the application is not limited thereto, and other winding forming processes can also be applicable.

[0172] In the embodiment, it can be seen that the second metal winding 32 is a spiral winding around the plurality of magnetic columns of the mouth-shaped magnetic core. The number of turns of the first metal winding 33 is one, which wraps around the plurality of magnetic columns of the mouth-shaped magnetic core, and only the mouth-shaped gap formed on the bottom surface of the magnetic core by etching, cutting, etc. forms the two ends (331 and 332) of the single-turn winding. FIG. 3C

[0173] Further, in combination with FIG. 3B to FIG. 3E , it is explained that in the embodiment, the two ends of the first metal winding 33 include a first end 331 and a second end 332 (as shown in FIG. 3C ), and the first pin V0 and the second pin D2 (as shown in FIG. 3D ) are respectively formed on the outer surface of the transformer module. The second metal winding 32 also has a first end and a second end, but because the first end and the second end of the second metal winding 32 are covered by the insulating layer, etc., the third pin P1 and the fourth pin P2 (as shown in FIG. 3D ​As shown in the figure, the first pin V0, the second pin D2, the third pin P1 and the fourth pin P2 are all arranged on the first surface (for example, the bottom surface) of the transformer module. In the embodiment, the first surface of the transformer module is arranged on the outer surface of the first metal winding, or the distance between the first surface and the outer surface of the first metal winding is close, for example, less than 1 mm, so that the pins on the first surface of the whole module are almost arranged on the same horizontal plane, which facilitates the assembly and connection of the outside. However, the present application is not limited thereto.

[0174] The transformer module is connected with an external circuit (for example, a switch module) through the first pin V0, the second pin D2, the third pin P1 and the fourth pin P2 (as shown in the figure). FIG. 3E As shown in the figure, the first pin V0, the second pin D2, the third pin P1 and the fourth pin P2 are all arranged on the first surface (for example, the bottom surface) of the transformer module. In the embodiment, the first surface of the transformer module is arranged on the outer surface of the first metal winding, or the distance between the first surface and the outer surface of the first metal winding is close, for example, less than 1 mm, so that the pins on the first surface of the whole module are almost arranged on the same horizontal plane, which facilitates the assembly and connection of the outside. However, the present application is not limited thereto.

[0175] The first pin V0, the second pin D2, the third pin P1 or the fourth pin P2 can be in various shapes such as square or circle.

[0176] Alternatively, the first pin V0, the second pin D2, the third pin P1 and the fourth pin P2 in the above embodiment can also not be arranged on the same surface of the transformer module, for example, the first pin V0 and the second pin D2 can be arranged on the first surface of the transformer module, and the third pin P1 and the fourth pin P2 can be arranged on the second surface of the transformer module, wherein the first surface and the second surface are different surfaces.

[0177] It should be noted that in the prior art, the impedance of the inner circle of the same layer winding is smaller than that of the outer circle due to the different radii of different parts of the same layer winding in the multi-layer PCB winding structure transformer, so the current distribution on the same layer winding is not uniform, and the loss of the winding is large. In addition, for the implementation technology of the via, the inner layer winding of the multi-layer PCB winding also needs to be connected to the surface layer through the via, but the diameter of the via is large, usually greater than 150 microns, and the distance between the vias is also usually greater than 150 microns due to the consideration of structure and wiring pattern definition. In the embodiment, because the rigid PCB board is no longer arranged, the first via and the second via can be directly formed on the first insulating layer by laser drilling, so that the diameter of the first via and the second via is small, and the space utilization of the transformer module can be further improved. However, the present application is not limited thereto.

[0178] Further, by adjusting the electroplating agent, a better electroplating filling rate can be achieved, and even the first via and the second via can be filled with copper layer, so as to achieve the purpose of reducing the loss of the winding.

[0179] Furthermore, as mentioned above, existing technologies typically employ a multi-layer PCB metal winding parallel connection method. Especially in low-voltage, high-current output applications, when using a multi-layer PCB winding structure, the number of PCB layers is usually large. For example, in server motherboard power supplies, the number of PCB winding layers is approximately 10. The inner windings of the multi-layer PCB winding need to be connected to the surface layer via vias. However, these vias are relatively long, have high impedance, and cause significant winding losses. In some embodiments of this application, since the thickness of the first insulating layer and other insulating layers is typically less than 200 micrometers, the first and / or second vias are shorter and have lower impedance. Therefore, these first and second vias can reduce winding losses.

[0180] Furthermore, regarding existing technology for another type of foil-wound transformer, although its windings employ a foil winding structure and the radii of each part of the same layer of winding are basically equal, meaning its current distribution is relatively uniform, the leads at the winding outputs are drawn from the side of the winding. This also results in an uneven current distribution near the outputs. In addition, the leads are longer, leading to correspondingly higher losses on the leads.

[0181] Based on this, this embodiment provides a transformer module that not only employs a foil-wound structure to achieve a more uniform current distribution on the windings, but also connects the output terminal of the inner winding to the transformer module's pins via a connector, such as a via, passing through at least partially covering the insulating layer and / or outer wiring layer, with the projection of the pin at least partially located within each wiring layer. This structure significantly reduces the pin length and the uneven current distribution in the windings caused by the pins. Furthermore, with... FIG. 3D As you can see, the second pin D2 and the first pin V0 almost cover the four magnetic pillars on the upper surface of the transformer. This distributed pin structure further improves the uniformity of current distribution on the winding, thereby greatly reducing winding losses.

[0182] like FIG. 3C and 3D As shown, the first metal winding is a continuous foil wound around a layer of copper foil on the magnetic core. This winding covers four magnetic core pillars, and its two ends are connected to two pins, V0 and D2, respectively. These two pins are connected to external circuits such as switching devices. Pins V0 and D2 are each present once. FIG. 3D As shown. FIG. 3F The structure shown is slightly different from the 3D model. FIG. 3F The metal winding is continuously wound around a portion of the magnetic pillars of a U-shaped magnetic core, for example, three pillars. The two ends of this winding are still connected to pins V0 and D2, with one pin each for V0 and D2. FIG. 3FFor example, from one side of the transformer, a is the inner length of the winding, b is the outer length of the winding, thus the average length of the winding W=(a+b) / 2, d is the average length of the pin on the winding, n is the ratio of the pin size to the winding size, n=d / W. Since the winding is connected to the external circuit through the pin, the size of d will affect the uniformity of the current distribution on the winding relative to the average length of the winding. For a certain average length of the winding, as d increases, the current distribution will be more and more uniform, and the winding loss will be smaller and smaller. As shown in FIG. 3G , FIG. 3G the horizontal coordinate is n, and the vertical coordinate P is the winding loss. It can be seen from the figure that as n increases, the corresponding winding loss will decrease significantly. Preferably, when d≥1 / 2W, the winding loss is small and tends to be stable. FIG. 3D In the figure, n=1, that is, the length of the pin is almost equal to the average length of the winding, thus FIG. 3D the pin structure in the figure can make the current distribution on the winding more uniform, and the corresponding winding loss is smaller. In this application, the magnetic core is not limited to the mouth-shaped type, and is also applicable to T-shaped, UU-shaped and UI-shaped magnetic cores.

[0183] Similarly, the pins of the secondary winding can also use multiple pins, as shown in FIG. 3H , FIG. 3H and FIG. 3F have basically the same structure, all containing a mouth-shaped magnetic core, and the magnetic core is covered with a layer of continuous winding wound on the three magnetic columns. Unlike FIG. 3F , FIG. 3H in the figure, one winding contains multiple first pins V0 and multiple second pins D2, that is, the number of first pins V0 and second pins D2 is greater than or equal to 2. As shown in FIG. 3H , the pin length contains three parameters: d1, d2 and d3, and the total length of the pin d=d1+d2+d3. FIG. 3HIn the figure, if V0 or D2 is only a single pin, the winding loss is still not small because the length of the pin of V0 or D2 is small, i.e. the ratio n of the length of the pin to the average length of the winding is small. When V0 or D2 is a plurality of pins, for example, three pins as shown in the figure, the length of the pin is greatly increased, and the ratio n of the length of the pin to the average length of the winding is increased, which makes the current distribution in the winding more uniform. It can be understood that the pin V0 and the pin D2 in the figure can be various shapes such as square or circular, for example, when the pin is circular, the length of the pin can be the diameter of the circle. Further, the more uniform the distribution of the plurality of first pins V0 and the plurality of second pins D2, the more uniform the current distribution in the winding, and correspondingly, the smaller the winding loss. In general, preferably, when the total length d of the first pin V0 or the second pin D2 is greater than or equal to 1 / 2 the length W of the winding, the winding loss is small and tends to be stable; the more the number of the first pin V0 or the second pin D2, the smaller the winding loss; the more uniform the distribution of the first pin V0 or the second pin D2, the smaller the winding loss.

[0184] In the embodiment 3C-3D, only one kind of schematic of the foil-wound transformer module is shown, i.e. the foil-wound structure winding covers the four magnetic columns of the magnetic core. In fact, the foil-wound structure winding can cover one magnetic column or a plurality of magnetic columns. The present application does not limit this.

[0185] Further, the transformer module provided by the embodiments of the present application is easy to expand in power, the magnetic columns can be entirely covered by the winding to improve the power of the transformer module, or the magnetic columns can be lengthened and the winding can be widened to increase the power of the transformer module.

[0186] Embodiment two

[0187] On the basis of the embodiment one, the embodiment two of the present application further provides a transformer module, a second insulating layer and a third wiring layer are sequentially arranged in the second wiring layer on the magnetic core of the transformer module, so that the second insulating layer is at least partially covered by the second metal winding.

[0188] The transformer module further comprises: a third metal winding formed in the third wiring layer and foil-wound on the magnetic core, wherein the third metal winding is also at least partially covered by the second insulating layer; and a fifth pin located on the first face of the transformer module and electrically connected to the covered third metal winding.

[0189] Specifically, FIG. 4A is a bottom view of the transformer module after the third metal winding is formed, FIG. 4B is a bottom view of a transformer module provided by an embodiment of the present application, FIG. 4C is FIG. 4B is an electrical schematic diagram of each end point of the transformer module shown. In combination with FIG. 4A to FIG. 4CTo explain, with FIG. 3A-3E Unlike the illustrated embodiment, this embodiment also includes a third wiring layer. From the outside in, the layers are: a first wiring layer, a first insulating layer, a second wiring layer, a second insulating layer, and a third wiring layer. These three layers form a first metal winding, a second metal winding, and a third metal winding, respectively. The second metal winding can serve as the primary winding P, the first metal winding as the secondary winding S2, and the third metal winding as the secondary winding S1, forming a "sandwich" structure where the secondary winding surrounds the primary winding. The third metal winding 34 is, for example, one turn. FIG. 4A As shown, the third metal winding 34 wraps around multiple magnetic pillars of the U-shaped magnetic core, and the U-shaped gap is formed only on the bottom surface of the magnetic core by etching, cutting and other methods to form the two ends of the single-turn winding (e.g., 341 and 342).

[0190] A second insulation layer, a second wiring layer, a first insulation layer, and a first wiring layer are disposed outside the third wiring layer, so the third metal winding is at least partially covered by the second insulation layer. The two ends of the third metal winding 34 include a first end 341 and a second end 342 (e.g., FIG. 4A As shown, the first end (e.g., D1) of the third metal winding 34 is connected to the outermost fifth pin D1 through a third via (not shown) for electrical connection with an external circuit. This third via passes through the first and second insulating layers and the second wiring layer. The fifth pin D1 can also be located on the first surface (e.g., the bottom surface). The second end (e.g., V0) of the third metal winding 34 is typically connected to one end of the first wiring layer winding, and is thus connected to the first pin V0 through a fourth via (not shown). This invention is not limited to this. The connection method between the first metal winding and the second metal winding and the external pins can be the same as in the aforementioned embodiment. The first metal winding connects to the first pin V0 and the second pin D2, and the second metal winding connects to the third pin P1 and the fourth pin P2. This will not be described further.

[0191] Specifically, the base insulation layer is selectively attached on the surface of the magnetic core by spraying or deposition, etc., which plays the role of insulation, enhances the bonding force and protects the magnetic core, but the application is not limited thereto, and the base insulation layer can also not be provided; in turn, a third wiring layer, for example, a copper layer, is provided on the surface by electroplating or chemical plating, etc.; again, a metal protective layer, such as a tin layer or a gold layer, etc., is electroplated or chemically plated on the surface of the third wiring layer; then the metal protective layer is pattern defined by a direct writing protection process, exposing the part of the third wiring layer that needs to be etched; then the etching of the third wiring layer pattern is carried out under the protection of the protective layer; finally, the protective layer is removed, forming a third metal winding, i.e. the secondary winding S1, and then a second insulation layer is attached on the third metal winding by spraying or deposition, etc.; in turn, a second wiring layer, which can be a copper layer, is provided on the surface by electroplating or chemical plating, etc.; again, a metal protective layer, such as a tin layer or a gold layer, etc., is electroplated or chemically plated on the surface of the second wiring layer; then the metal protective layer is pattern defined by a direct writing protection process, exposing the part of the second wiring layer that needs to be etched; then the etching of the second wiring layer pattern is carried out under the protection of the metal protective layer; finally, the protective layer is removed, forming a second metal winding, i.e. the primary winding P. Then a first insulation layer is attached on the second metal winding by spraying or deposition, etc.; in turn, a first wiring layer, which can be a copper layer, is provided on the surface by electroplating or chemical plating, etc.; again, a metal protective layer, such as a tin layer or a gold layer, etc., is electroplated or chemically plated on the surface of the first wiring layer; then the metal protective layer is pattern defined by a direct writing protection process, exposing the part of the first wiring layer that needs to be etched; then the etching of the first wiring layer pattern is carried out under the protection of the metal protective layer; finally, the protective layer is removed, forming a first metal winding, i.e. the secondary winding S2. But the application is not limited thereto, and other winding forming processes can also be applicable.

[0192] An optional way, as shown in FIG. 4B The fifth pin D1 is a plurality of, and the plurality of fifth pins D1 are located between the first pin V0 and the second pin D2. Further, the second pin D2 further includes a plurality of teeth 41, and the plurality of teeth 41 are arranged in a staggered manner with the plurality of fifth surface mount D1 pins. Optionally, the plurality of teeth 41 and the plurality of fifth surface mount D1 pins are uniformly staggered. The use of multiple fifth surface mount and multiple second pins can help to evenly distribute the current, and can be used to connect multiple groups of external devices, which can help to reduce impedance and improve integration, for example FIG. 15 It can be used to connect multiple switching modules. Optionally, the pins can be columnar or spherical, etc., and the application is not limited thereto.

[0193] Another optional way, FIG. 5 is a bottom view of another transformer module provided by an embodiment of the application, as shown in FIG. 5As shown, the fifth pin D1 is one, and the fifth pin D1 is located between the first pin V0 and the second pin D2. The magnetic core can include a through hole 61, and from the perspective of the bottom surface of the transformer module, the fifth pin D1 is partially around the through hole 61, for example, a C-shaped, the first pin V0 is a C-shaped around the through hole 61, and the second pin D2 is partially around the through hole 61. But the present application is not limited to this, by adjusting the position of the third pin P1 and the fourth pin P2, the first, second, and fifth pins can also form other shapes such as a square around the through hole. The C-shaped, square-shaped, and the like can increase the connection strength with the external module, and are suitable for connecting multiple modules.

[0194] Embodiment three

[0195] FIG. 6A And FIG. 6B are respectively an electrical schematic diagram of each end point of a power module provided by an embodiment of the present application, FIG. 6C and FIG. 6D are respectively a cross-sectional view of a power module provided by an embodiment of the present application, which is described in conjunction with FIG. 6A-FIG. 6D , the power module comprises:

[0196] A transformer module 71 as in various embodiments of the present application.

[0197] A switch module 72, the switch module 72 and the first surface (for example, the bottom surface with pins) of the transformer module 71 are in contact and electrically connected with the first pin V0 and the second pin D2.

[0198] Optionally, the switch module 72 includes a carrier board 74 and at least one power switch 73, as shown in FIG. 6A and FIG. 6C As shown, the switch module 72 includes at least one power switch 73, and the power switch 73 is electrically connected with the first pin V0; as shown in FIG. 6B and FIG. 6D As shown, in another embodiment, the switch module can also include at least one full-bridge circuit formed by interconnecting at least four power switch devices (such as MOSFET), and the power switch is arranged on the carrier board 74, and the full-bridge circuit is electrically connected with the first pin V0 and the second pin D2. According to the actual application of the circuit topology, different types of power switches can be selected to be electrically connected with the first pin V0 and / or the second pin D2, and the present application is not limited to this, the power switch can also be connected with other pins, and each power switch shown in the figure can be selected by multiple power switches in parallel according to the actual output power of the transformer. Among them, as shown in FIG. 6C and FIG. 6D As shown, the power switches can all be located on the lower surface of the transformer module, or the power switches can also be located on the upper surface of the transformer module, and the present application does not limit this.

[0199] The power switch can be a diode, a Metal-Oxide-Semiconductor Field-Effect Transistor (MOSFET), an Insulated Gate Bipolar Transistor (IGBT), or the like.

[0200] Specifically, one or more parallel power switches SR can be directly integrated in a carrier board by an embedded process to form the switch module, but the application is not limited thereto. The power switch can be arranged just below the pin of the switch module to facilitate connection with the pin. In combination with FIG. 3D In this embodiment, although the number of the first pin V0 and the second pin D2 is one, if the size of the power switch or the size of the pin of the switch module connected externally is smaller than the size of the transformer module, a plurality of parallel SRs can be connected to the pin as shown in the figure, and the SRs can be evenly distributed on the pin or unevenly distributed. FIG. 5 The embodiment shown can also be similarly arranged. In combination with FIG. 4B In this embodiment, the teeth of the plurality of fifth pins D1 and the plurality of second pins D2 can be used to connect a plurality of power switches. FIG. 6E The bottom view of the switch module provided by an embodiment of the application is shown in FIG. 8. FIG. 6E As shown, the lower surface of the carrier board can form the output pin (PIN) of the transformer power unit, such as VOUT, GND, and the like. Then the corresponding transformer module is welded to the carrier board to form a power module, as shown in FIG. 6C 、 6D .

[0201] Alternatively, one or more parallel SRs are welded on the surface of the carrier board, and then the switch module is formed by a molding process. The other surface of the carrier board forms a pad corresponding to the transformer module, and the transformer module is welded to the surface of the carrier board to form a power module.

[0202] Further, the power module further comprises a capacitor module, which is arranged on the carrier board and adjacent to the transformer module, as shown in FIG. 6F and the like. The capacitor module can be electrically connected to the second pin D2, or as shown in FIG. 7 and the like. The capacitor module can also be electrically connected to the first pin V0, but the application is not limited thereto. The power module can also include an LLC power unit, a controller, and the like, so that the power module serves as an LLC converter. Specifically, FIG. 6F The cross-sectional view of a power module provided by an embodiment of the application is shown in FIG. 11. FIG. 6FAs shown, Co is the output capacitor.

[0203] It should be noted that the power modules mentioned above are not limited to LLC converters, but are also applicable to any circuit containing a transformer module, such as flyback converters, full-bridge circuits, etc.

[0204] Example 4

[0205] Based on Embodiment 3, this application also provides a power module, wherein the power module includes a transformer module similar to that in Embodiment 2, with a second insulating layer and a third wiring layer sequentially disposed on the magnetic core, the second insulating layer being at least partially covered by a second metal winding. The transformer module further includes: a third metal winding formed on the third wiring layer and wound around the magnetic core, wherein the third metal winding is at least partially covered by the second insulating layer; and a fifth pin located on the first surface (e.g., the bottom surface) of the transformer module, the first end of the third metal winding being electrically connected to the fifth pin D1 through a third connector (e.g., a via), the second end of the third metal winding being electrically connected to the first pin V0, and the remainder not described further.

[0206] in, FIG. 7 An electrical schematic diagram of each terminal of a power module is provided as an embodiment of this application, such as... FIG. 7 As shown, after the transformer module and the switch module are stacked, the switch module will also be electrically connected to the fifth pin D1.

[0207] Furthermore, such as FIG. 7 As shown, the power module also includes a first power switch (SR) and a second power switch (SR), wherein the first terminal of the first power switch and the second pin D2 are electrically connected, the first terminal of the second power switch and the fifth pin D1 are electrically connected, and the second terminal of the first SR and the second terminal of the second SR are electrically connected. However, the present invention is not limited thereto, and each power switch shown in the figure can actually be equivalent to multiple power switches connected in parallel according to the power level of the device.

[0208] Furthermore, the power module also includes a capacitor module, which may serve different functions, such as an LC resonant capacitor or an output capacitor; however, this invention is not limited thereto. FIG. 6F As shown, Co can be an output capacitor. This capacitor module can be electrically connected to the first pin V0. The capacitor can be placed in many locations; for example, the capacitor module can be located on the carrier board and adjacent to the transformer module, such as... FIG. 6F As shown; it can also be located on the same side of the carrier plate as the switching device SR; it can also be embedded in the carrier plate; or placed in the window of the transformer, for example. FIG. 6FWhen the transformer core is a U-shaped core, the capacitor can be placed in the window of the core, etc.; or even placed on the upper surface of the core, while the SR device is placed on the lower surface of the core. The power module may also include LLC primary-side power units, controllers, etc., so that the power module can function as an LLC converter.

[0209] It should be noted that the power modules mentioned above are not limited to LLC converters, but are also applicable to any circuit containing a transformer module, such as flyback converters, full-bridge circuits, etc.

[0210] As can be seen, power modules are easy to produce in a modular manner. First, multiple SRs are integrated on a carrier board to form a switch module. Then, multiple transformer modules are surface-mounted onto the switch module and finally cut. Thus, multiple power modules can be produced at once, but this invention is not limited thereto.

[0211] Furthermore, the power switch and multiple output pins of the transformer module are directly connected, resulting in low connection loss; the primary and secondary circuits of the transformer module are directly coupled together, resulting in low winding AC impedance and low AC loss, but the present invention is not limited thereto.

[0212] In some embodiments, such as Embodiments 1 to 4, the correspondence of each pin is as follows (but not limited to):

[0213] The first pin corresponds to V0, through... FIG. 3E , 4C As can be seen from Figures 6A, 6B, and 7, they can correspond to the first end of the first metal winding S2, the second end of the third metal winding S1, etc., and can be used as the output endpoints of the module.

[0214] The second pin corresponds to D2, through... FIG. 3E , 4C As can be seen from Figures 6A, 6B, and 7, it corresponds to the second end of the first metal winding S2 and can be used to connect with power switches, secondary grounding, etc.

[0215] The third pin corresponds to P1, and the fourth pin corresponds to P2, which can correspond to the two ends of the second metal winding P respectively;

[0216] Pin 5 corresponds to D1, through FIG. 3E , 4C As can be seen from Figures 6A, 6B, and 7, it can correspond to the first end of the third metal winding (as the secondary winding S1) and can be used to connect with power switches, secondary grounding, etc.

[0217] However, in other embodiments of this application, such as Embodiments 5 to 9, for ease of description, the electrical connection points corresponding to each pin are not the same as the corresponding electrical connection points in the foregoing embodiments, and this application is not limited thereto.

[0218] Example 5

[0219] In the above embodiments, each winding of the transformer can be located in the same wiring layer, but the present invention is not limited thereto. FIG. 8 What is shown is FIG. 5 The transformer module is shown in a cross-sectional view along AA'. This view shows that the windings are located in the first, second, and third wiring layers, which are arranged sequentially from the outside in. FIG. 8 In the diagram, the via connecting the first lead of the third wiring layer to the second pin D1 is indicated by a dashed line because this via and the via of the other lead of the winding are not on the same cross section.

[0220] In reality, windings can also be placed in staggered layers, meaning that the same winding can be located in different wiring layers, such as two wiring layers, for example, the first wiring layer, the first insulation layer, and the second wiring layer are arranged sequentially from the inside to the outside on the magnetic core. FIG. 9A , FIG. 9B A cross-sectional view of this winding arrangement is given. (For example...) FIG. 9A and FIG. 9B As shown, 191 is the magnetic core; the first metal winding, with foil wound around the magnetic core 191, includes a first winding 1922 formed on the first wiring layer and a second winding 1921 formed on the second wiring layer. The first end of the first winding 1922 is electrically connected to the first end of the second winding 1921 through a via, and the second end of the first winding 1922 is electrically connected to the first pin V0 through a via. The second end of the second winding 1921 forms the second pin D1. The second metal winding, also with foil wound around the magnetic core 191, includes a third winding 1941 disposed on the first wiring layer and a fourth winding 1942 formed on the second wiring layer. The second end of the third winding 1941 is connected to the pin V0 through a via. As shown in the figure, the first end of the third winding 1941 is connected to the first end of the fourth winding 1942 through a via, and the second end of the fourth winding 1942 forms the third pin D2. Thus, the first and second metal windings are formed as shown. FIG. 7 The connection structure of the secondary windings S1 and S2 of the transformer is shown. FIG. 7 The winding P of the transformer is FIG. 9A-9B The third metal winding 193, which is located in the third wiring layer, is a foil winding. The third wiring layer and the second insulating layer can be sequentially located between the first insulating layer and the second wiring layer. FIG. 7 The secondary windings S1 and S2 are arranged using a staggered layering method, which is different from... FIG. 8 The arrangement of the same winding on the same wiring layer, as shown, will greatly improve the symmetry between the two windings, thus significantly improving the current sharing effect of the current flowing through the first and second SRs during circuit operation. Besides... FIG. 7 The windings in the circuit can be arranged in this staggered manner.FIG. 6A-FIG. 6F The winding in the transformer can also be arranged in this way, then the second end of the third segment of the second metal winding is connected to a pin different from V0 on the surface of the transformer through a via. In this way, four pins will be formed on the surface of the transformer, and the first and second metal windings also become two independent windings, as shown in FIG. 6B The winding P in the transformer and the winding S2.

[0221] The design of the pins can be similar to that in other embodiments of the present application, for example, the third pin D2 is a plurality of pins, the second pin D1 includes a plurality of teeth, and the plurality of teeth are arranged alternately with the plurality of third pins D2; or, the second pin D1 and the third pin D2 are both a plurality of pins, and the plurality of second pins D1 and the plurality of third pins D2 are arranged alternately; or, as shown in FIG. 9C FIG. 9C is a bottom view of the transformer in an embodiment of the present application, including a first pin V0, a second pin D1, and a third pin D2, wherein the first pin V0 is between the second pin D1 and the third pin D2, and the length of each pin is almost equal to the average length of the winding; the first, second, and third pins can be a square or as shown in FIG. 9D The plurality of pins are arranged on the partial winding, and the plurality of pins are arranged symmetrically, but the present application is not limited thereto.

[0222] The corresponding power module can include a switching module. Similarly to FIG. 7 , the switching module includes a plurality of first SRs and a plurality of second SRs; the first end of the first SR is connected to the first pin D1, the first end of the second SR is connected to the third pin D2, and the second end of the first SR is electrically connected to the second end of the second SR; according to the different pins of the transformer, the plurality of first SRs (i.e. SR1 in FIG. 9E ) and the plurality of second SRs (i.e. SR2 in FIG. 9E ) can be arranged in two separate rows, as shown in FIG. 9E FIG. 9E is a schematic view of a part of the transformer and the switching elements arranged thereon in FIG. 9C . The part of the transformer module includes three pins D1, D2, and V0, the pin V0 is between D1 and D2, the transformer module has a switching module including a plurality of SR1s and a plurality of SR2s, the plurality of SR1s and the plurality of SR2s are arranged in two separate rows, and the switching module contacts one side of the transformer. In addition, the power switches can also be arranged in the same row, wherein the SR1s and the SR2s are arranged alternately, but the present application is not limited thereto. Of course, the switching module can also include a carrier plate, and the switches can be placed on the carrier plate or embedded in the carrier plate.

[0223] ​​Further, the power module can also include a capacitor module, which includes a plurality of capacitor units. The capacitor module can be located on the carrier board and arranged adjacent to the transformer module, as shown in FIG. 6F . Alternatively, the capacitor module can also be located below the carrier board, as shown in FIG. 9F . The capacitor Co is located below the power switch, and the capacitor module is located at the lower end of the SR. Of course, Co can also be embedded in the carrier board, or placed on the other side of the transformer opposite to the switch module, for example, on the upper side of the transformer module in FIG. 9F . Co can also be placed in the window of the magnetic core. In summary, the capacitor module can be located in various positions.

[0224] Embodiment Six

[0225] In the previously described embodiments, the transformer winding is formed by electroplating, and the pin is led out by the via. However, the present application is not limited thereto. As shown in FIG. 8 , the winding of the transformer is a winding layer formed by electroplating or electroless plating, and the pin D1, V0 is connected to the inner winding by the via. However, the present application is not limited thereto.

[0226] In fact, the transformer winding can also be formed by winding a metal foil, such as a copper foil. FIG. 10A For the cross-sectional view of the transformer in an embodiment of the present application, as described in Embodiment Two, the transformer module includes, from the outside to the inside, a first metal winding 1104, a second metal winding 1103, and a third metal winding 1102. The third metal winding is filled with an initial insulating layer between the third metal winding and the magnetic core. The third and second metal windings are filled with a second insulating layer therebetween. The second and first metal windings are filled with a first insulating layer therebetween. The second metal winding 1103 can serve as the primary winding P, the third metal winding 1102 can serve as the secondary winding S1, and the first metal winding 1104 can serve as the secondary winding S2, forming a "sandwich" structure in which two secondary windings are wrapped around the primary winding. The third metal winding 1102 is a whole copper layer wrapped around the magnetic core column 1101, so that the magnetic core column 1101 is at least partially covered by the initial insulating layer and the third metal winding 1102. Similarly, the third metal winding 1102 is at least partially covered by the second insulating layer and the second metal winding 1103, and the second metal winding 1103 is at least partially covered by the first insulating layer and the first metal winding 1104.

[0227] Similar to Embodiment 2, the third metal winding 1102 has two ends, divided into a first end and a second end. The first end is connected to the outermost fifth pin, such as pin D1, for electrical connection with the outside. The second end of the third metal winding 1102 is usually connected to one end of the first metal winding 1104 and commonly connected to the outermost first pin, such as pin V0. Different from Embodiment 2, the pins led out from the first end and the second end of the third metal winding 1102 are not led out through vias. FIG. 10B-10F One of its manufacturing methods is introduced, that is, the method of integrally forming with a metal foil such as copper foil.

[0228] First, a whole piece of metal foil, such as copper foil, is cut into the structure shown in FIG. 10B (i.e., the developed view of the third metal winding). On two parallel sides of the copper foil, "丄" - shaped structures as shown in the figure are respectively cut out. These structures are used to form the pins 1001 and 1002 of this layer of winding; then, the copper foil is folded according to the dotted lines shown in the figure. The folded shape is as shown in FIG. 10C . Then, a long strip of copper foil is used as the second metal winding of the transformer and wound around the surface of the third metal winding, avoiding the upright pins 1001 and 1002 of the third metal winding, as shown in FIG. 10D ; finally, the first metal winding is manufactured using a process similar to that for manufacturing the third metal winding. A whole piece of copper foil is cut and folded into the first metal winding as shown in FIG. 10E . At one end of the first metal winding, holes 1003 corresponding to the pins 1001 and 1002 of the third metal winding are cut out to allow the pins of the third metal winding to extend through these holes (in the figure, two holes 1003 respectively allow the pins 1001 and 1002 to pass through. Actually, the two holes can also be made into one hole); finally, the first - end pins of the third metal winding are insulated, and then bent and laid flat on the surface of the first metal winding to form the fifth pin D1. The second - end pins of the third metal winding are bent and laid flat on the surface of the first metal winding for connection to form the first pin V0, as shown in FIG. 10F -G.

[0229] Optionally, there can be a plurality of the first, fifth, and second pins. And a plurality of first pins V0 are in the middle of the fifth pin D1 and the second pin D2. The first, second, and fifth pins are each in a row, as shown in FIG. 10G . This application is not limited thereto.

[0230] In this embodiment, the inner winding, connector, and pin are integrally formed, and the pin passes through the insulation layer between the windings and the wiring layer where the outer winding is located. For example, the pin of the third metal winding passes through the insulation layer between the third winding and the second winding, the insulation layer between the second winding and the first winding, and the second and first windings, and then bends on the surface of the first winding.

[0231] Taking the insulation of the third metal winding 1102 as an example, the insulation requirements for the third metal winding include an initial insulation layer on its inner side and a second insulation layer on its outer side. The initial insulation layer is used for insulation with the magnetic core post 1101, and the second insulation layer is used for insulation with the second metal winding 1103. The required thickness of the insulation layer depends on the interlayer withstand voltage and the interlayer distributed capacitance; for example, in this case, the required thickness of the insulation layer is 70 μm. Other requirements for the insulation layer include having a certain degree of flexibility.

[0232] To address these needs and effectively handle the insulation layers between different metal wiring layers and between the wiring layers and the magnetic core posts, this application proposes a novel insulation layer manufacturing method. Taking the insulation of any metal winding as an example, the manufacturing method and process of the insulation layer are specifically described. The first step involves cutting and shaping a metal foil, such as... FIG. 10B The third wiring layer metal shown undergoes surface roughening treatment, including mechanical polishing or chemical roughening / browning, with chemical browning being the optimal method. The purpose of surface roughening is to increase the contact surface area between the metal layer and the insulating material, thereby increasing the adhesion of the insulating material and ensuring that delamination or peeling does not occur between the metal layer and the insulating material during subsequent bending. The second step involves forming the first insulating layer on the roughened metal layer 1102, creating the inner base insulating layer, such as... FIG. 10B-1 As shown, 1102 is the metal layer, and 1006 is the insulating layer. Insulation methods include electroplating, spraying, or printing. Among these, electroplating is preferred because it has the least requirement for the shape of the metal layer, provides more reliable insulation for hard-to-handle areas such as metal edges and corners, and exhibits better adhesion. For example, acrylic electroplating coatings can be used, composed of polyacrylic resin and polyurethane (commonly known as PU) hardeners. At locations where connection terminals are needed, 1007 can be avoided by pre-covering and masking. The third step involves forming a second insulating layer after the first insulating layer is formed, creating an outer auxiliary insulating layer, such as... FIG. 10B-2 As shown. The thickness of the insulating layer that can be produced by electroforming is relatively limited, typically between 0.1 and 30 μm. Therefore, when the required insulating layer thickness is greater than 30 μm, as shown in this example, a second insulating layer forming is required. The second insulating layer forming can be achieved, for example, by applying an insulating adhesive, such as... FIG. 10B-2As shown, the printed insulation glue 1008 is provided. Of course, the auxiliary insulation layer method is not limited to printing insulation glue, and can also be made by photoresist film pressing, local dispensing, etc. As an example, the auxiliary insulation layer material can be selected from a photosensitive photoresist such as an epoxy resin material. In order to avoid cracking of the insulation layer when the metal layer is bent, only local printing can be performed, such as FIG. 10B-2 and FIG. 10B-3 as shown. FIG. 10B-2 is a cross-sectional view of the metal layer before bending, FIG. 10B-3 is a cross-sectional view of the metal layer after bending. As can be seen in the figure, no insulation material is printed in the corner part that needs to be bent. The second insulation forming increases the total insulation layer thickness. Of course, this step is not necessary, and in cases where the thickness requirement is not high, the first insulation layer forming can meet the requirements. Finally, after the completion of the insulation layer, a layer of adhesive layer can be coated to realize the bonding and fixing between multiple metal wiring layers.

[0233] A manufacturing process of a metal winding is shown in FIG. 10B-4 Step S1, cutting the first metal foil to form a connecting piece and a pin; Step S1.1, roughening the surface of at least one of the first metal foil and the second metal foil; Step S2.1, performing a first insulation treatment on the surface of at least one of the first metal foil and the second metal foil to form an inner basic insulation layer; Step S2.2, performing a second insulation treatment on the surface of the metal foil forming the basic insulation layer to form an outer auxiliary insulation layer; Step S2.3, applying an adhesive layer to the surface of at least one of the first metal foil and the second metal foil; Step S3, bending the first metal foil to form a first metal winding, which is wrapped around a magnetic core. Step S4, wrapping the second metal foil at least partially around the surface of the first metal winding to form a second metal winding, and the pin of the first metal winding passes through the second metal winding. Step S5, cutting the third metal foil to form a via hole or a gap, bending the third metal foil and wrapping it around the surface of the second metal winding to form a third metal winding, and the pin of the first metal winding passes through the via hole or the gap.

[0234] wherein Step S1.1, Step S2.2, and Step S2.3 are optional steps. It should be noted that the order of the above steps is not limited in the present application, for example, Step S2.1 and Step S2.2 can be performed before Step S1 or after Step S1. In some embodiments, the second metal foil in Step S4 is a long strip-shaped copper foil, which serves as a second metal winding and is wound around the surface of the first metal winding. During winding, a via hole or a gap is formed to allow the pin of the first metal winding to pass through.

[0235] The corresponding power module can refer to the power module in Embodiment Five, which will not be described here.

[0236] In the circuit diagram shown in FIG. 7 If the secondary winding S1 and / or S2 is segmented to lead out connection terminals on different faces of the transformer module, the position of the first SR and / or the second SR does not have to be limited to the bottom face of the transformer module, but can be flexibly arranged on different faces by, for example, FIG. 12A and 12B The pins S1', D1 and / or S2', D2 are electrically connected in series in the corresponding metal winding, and the device can be flexibly arranged on different faces, which is advantageous for optimizing the spatial distribution. This will be further described in Embodiments 7 to 9.

[0237] Embodiment 7

[0238] FIG. 11A and FIG. 11B are respectively a structural schematic diagram of a transformer module provided in an embodiment of the present application, FIG. 12A is a sectional view of an AB line section of a transformer module provided in an embodiment of the present application, FIG. 11A is a sectional view of an AB line section of a transformer module provided in an embodiment of the present application, FIG. 12B , FIG. 11B The dashed lines in FIG. 12A , 12B indicate omitted parts. Specifically, in combination with FIG. 11A and FIG. 12A , the transformer module comprises:

[0239] a magnetic core 91, wherein the magnetic core 91 is sequentially provided with a first wiring layer, a first insulating layer, a second wiring layer, a second insulating layer and a third wiring layer from inside to outside.

[0240] A first metal winding is foil-wound on the magnetic core 91 and comprises a first segment winding 922 formed on the first wiring layer and a second segment winding 921 formed on the second wiring layer. A first end of the first segment winding 922 is electrically connected to a first pin D1 through a via. A second end of the first segment winding 922 is electrically connected to a second pin V0 through a via, and a first end of the second segment winding 921 forms a third pin S1'. The first pin D1 and the third pin S1' are both located on a first face of the transformer module, and a second end of the second segment winding 921 forms a fourth pin GND. The second pin V0 and the fourth pin GND are both located on a second face of the transformer module. When a corresponding electronic device, for example, a switching element, is electrically connected to the first pin D1 and the third pin S1', the first segment winding 922 formed on the first wiring layer and the second segment winding 921 formed on the second wiring layer are electrically connected in series. A third metal winding 93 is formed on the third wiring layer and foil-wound on the magnetic core 91. In an application embodiment, the third metal winding 93 can serve as a primary winding P, and the first metal winding can serve as a secondary winding S1, for example, corresponding to FIG. 3E.

[0241] Optionally, in combination with FIG. 11B and FIG. 12B As shown in the figure, the transformer module further comprises:

[0242] The second metal winding, the foil winding around the magnetic core 91, comprises a third segment winding 941 formed on the first wiring layer and a fourth segment winding 942 formed on the second wiring layer, the first end of the third segment winding 941 is connected to the fifth pin D2 through the via 95, the second end of the third segment winding 941 is electrically connected to the second pin V0, the first end of the fourth segment winding 942 forms the sixth pin S2', and the second end of the fourth segment winding 942 is electrically connected to the fourth pin GND. The fifth pin D2 and the sixth pin S2' are both located on the first surface of the transformer module. In an application embodiment, the third metal winding 93 can be used as the primary winding P, the first metal winding can be used as the secondary winding S1, and the second metal winding can be used as the secondary winding S2, for example, corresponding to FIG. 4C .

[0243] Optionally, when the corresponding electronic device, such as a switching element, is electrically connected to the fifth pin D2 and the sixth pin S2', the third segment winding 941 formed on the first wiring layer and the fourth segment winding 942 formed on the second wiring layer are electrically connected in series.

[0244] Optionally, the transformer module can comprise the first metal winding and the second metal winding, and the third metal winding and the wiring layer and the insulating layer corresponding thereto can be omitted, and the first metal winding and the second metal winding are used as the primary winding P and the secondary winding S1 of the transformer module, respectively, for example, corresponding to FIG. 3E The application is not limited thereto.

[0245] Optionally, the via can be located at about 1 / 2 of the length of the first metal winding 92 and the second metal winding, for example, when the number of turns of the first metal winding and the second metal winding is one, the first segment winding 922, the second segment winding 921, the third segment winding 941 and the fourth segment winding 942 are all wound around the magnetic core 91 for half a turn, but the application is not limited thereto, and the number of turns of the first metal winding and the third metal winding is not limited to one.

[0246] Optionally, the first surface and the second surface of the transformer module are two opposite surfaces. For example, the first surface of the transformer module can be the upper surface of the transformer module, and the second surface of the transformer module can be the lower surface of the transformer module. Alternatively, the first surface of the transformer module can be one side surface of the transformer module, and the second surface of the transformer module can be the other side surface of the transformer module. The application does not limit the specific positions of the first surface and the second surface.

[0247] Optionally, the magnetic core is a mouth-shaped core, a ring-shaped core, an I-shaped core or a C-shaped core.

[0248] Optionally, the number of turns of the first metal winding is one, the number of turns of the third metal winding is a plurality to form a spiral winding around the magnetic core, and the number of turns of the second metal winding is one.

[0249] The distribution of the first pin D1, the fifth pin D2, the third pin S1' and the sixth pin S2' of the transformer module is described as follows:

[0250] An optional way, FIG. 13A A top view of the transformer module provided by an embodiment of the present application is shown in FIG. 1, wherein: FIG. 13A As shown in the figure, the first pin D1 is a plurality, the fifth pin D2 is a plurality, and the plurality of first pins D1 and the plurality of fifth pins D2 are arranged alternately, and the plurality of first pins D1 and the plurality of fifth pins D2 are both located between the third pin S1' and the sixth pin S2'.

[0251] Another optional way, FIG. 13B A top view of the transformer module provided by another embodiment of the present application is shown in FIG. 2, wherein: FIG. 13B As shown in the figure, the first pin D1 is a H-shaped pin, the fifth pin D2 is a H-shaped pin, and the first pin D1 and the fifth pin D2 are both located between the third pin S1' of the H-shaped pin and the sixth pin S2' of the H-shaped pin. When the pins on the first surface are arranged as the first pin D1, the fifth pin D2, etc., the pins on the first surface can also be arranged as C-shaped pins or other shapes, which are not limited in the present application.

[0252] FIG. 14A A bottom view of the transformer module provided by an embodiment of the present application is shown in FIG. 3, wherein: FIG. 14A As shown in the figure, the output PINs, such as VOUT, GND, etc., can be formed on the lower surface of the transformer module. FIG. 14B A bottom view of the transformer module provided by another embodiment of the present application is shown in FIG. 4, wherein: FIG. 14B As shown in the figure, the output PINs, such as VOUT, GND, etc., can be formed on the lower surface of the transformer module.

[0253] An embodiment of the present application further provides a transformer module. Since the transformer winding of the foil winding structure is directly wrapped on the transformer magnetic column, the equivalent diameters of each part of the foil winding structure winding are similar, the equivalent impedances are similar, and the effect of uniform current distribution of the winding is achieved.

[0254] Embodiment eight

[0255] FIG. 15 A sectional view of the power module provided by another embodiment of the present application is shown in FIG. 5, wherein the power module comprises: FIG. 15 As shown in the figure, the power module comprises:

[0256] A transformer module 121 as in embodiment seven.

[0257] a switch module 122, the switch module 122 and the first surface (for example, the upper surface with pins) of the transformer module 121 are in contact and electrically connected with the first pin D1, the third pin S1', the fifth pin D2, and the sixth pin S2'.

[0258] Optionally, the switch module 122 comprises a carrier board 124 and at least two power switches (SR) 123, as shown in FIG. 15 The switch module 122 comprises power switches (SR) 123, and the power switches 123 are arranged on the carrier board 124. At least one first SR is electrically connected with the first pin D1 and the third pin S1', and at least one second SR is electrically connected with the fifth pin D2 and the sixth pin S2'. Wherein, the power switches can be located on the lower surface of the transformer module, or the power switches can be located on the upper surface of the transformer module, which is not limited in the present application.

[0259] Embodiment Nine

[0260] FIG. 16 The top view of the power module provided for another embodiment of the present application is shown in FIG. 16 The power module comprises:

[0261] a transformer module as in Embodiment Seven;

[0262] at least one first SR is in contact with the first surface (for example, the upper surface with pins) of the transformer module and is electrically connected with the first pin D1 and the third pin S1';

[0263] at least one second SR is in contact with the first surface (for example, the upper surface with pins) of the transformer module and is electrically connected with the fifth pin D2 and the sixth pin S2'.

[0264] Wherein, the SR can be a diode, MOSFET or IGBT, etc. The above-mentioned first SR and second SR can be packaged as a switch module respectively, or can be integrated into a switch module, which is not limited in the present application.

[0265] Specifically, one or more bared dies of parallel SRs are directly integrated in a carrier board through an embedded process to form the switch module. The corresponding pads of the transformer module are formed on the lower surface of the carrier board, and the switch module and the transformer module are welded together to form the power module.

[0266] Alternatively, one or more parallel SRs are welded on the surface of the carrier board, and then the switch module is formed through a molding process. The other surface of the carrier board forms the corresponding pads of the transformer module, and the transformer module is welded on the surface of the carrier board to form the power module.

[0267] Further, the power module further comprises a capacitor module, the capacitor module is in contact with the second face of the transformer module and is electrically connected with the second pin and the fourth pin. Specifically, the power module can further comprise an LLC primary side power unit, a controller, etc. to make the power module as an LLC converter. Alternatively, as shown in the following, the capacitor module comprises a Co, wherein Co is an output capacitor. FIG. 16

[0268] Alternatively, the power module can only comprise a primary side power unit, a resonant unit, a controller, an output capacitor, etc.

[0269] In the embodiments seven to nine, the first metal winding, the second metal winding S1 and / or S2 in the circuit schematic diagram shown in the following can be segmented respectively to form connection terminals on different faces of the transformer module. FIG. 7

[0270] In the embodiments seven to nine and other embodiments, the corresponding of each pin is (but not limited to) as follows:

[0271] The first pin corresponds to D1, the third pin corresponds to S1, and the two ends of a switch (for example, a diode) can be electrically connected with the first pin and the third pin respectively to form a connection relationship of the switch and the first metal winding in series, as shown in the following figures. FIG. 7 12A The second pin corresponds to V0, and the second pin can be used as an output terminal of the module, as shown in the following figures.

[0272] The fourth pin corresponds to GND and can be used for connection with a secondary side ground, etc. FIG. 7 The fifth pin corresponds to D2, and the sixth pin corresponds to S2. The two ends of a switch (for example, a diode) can be electrically connected with the fifth pin and the sixth pin respectively to form a connection relationship of the switch and the first metal winding in series, as shown in the following figures.

[0273] But in the embodiments seven to nine of the present application, for the convenience of description, the electrical connection points corresponding to each pin are not the same as the electrical connection points corresponding to each pin in the aforementioned embodiments one to four, and the present application is not limited thereto.

[0274] FIG. 7 12B

[0275] But in the embodiments seven to nine of the present application, for the convenience of description, the electrical connection points corresponding to each pin are not the same as the electrical connection points corresponding to each pin in the aforementioned embodiments one to four, and the present application is not limited thereto.

[0276] ​​​​​​The transformer module of each of the foregoing embodiments can also lead out two ends of the third metal winding to a pin, which can be led out to the first face, the second face, or other faces, and the application is not limited thereto; the shape of each pin is not limited to the shape shown in the character-shaped, C-shaped, or other shapes shown in the drawings, and can be flexibly changed according to actual application.

[0277] The pin in each of the foregoing embodiments is a surface-mounted pin, and in fact, the pin can also be in other forms, such as a straight-in pin, etc.

[0278] Each metal winding of the transformer module of each of the foregoing embodiments can flexibly correspond to a primary winding, a secondary winding, etc. of different types of transformers, for example, can be used in a common transformer such as FIG. 3E , can also be used in a secondary-side tapped transformer (related to two secondary windings in series), can also be used in a plurality of secondary windings independent transformer, etc., and the application is not limited thereto.

[0279] It should be noted that the power module described above is not limited to an LLC converter, but is also applicable to any circuit containing a transformer module, such as a flyback converter, a full-bridge circuit, etc.

Claims

1. A transformer module, characterized by The transformer module comprises: a magnetic core, a first wiring layer, a first insulating layer and a second wiring layer are sequentially arranged on the magnetic core from inside to outside; a first metal winding, foil-wound on the magnetic core, comprising a first segment winding formed on the first wiring layer and a second segment winding formed on the second wiring layer, at least part of the first segment winding is located on a first side of the magnetic core, and at least part of the second segment winding is located on a second side of the magnetic core, the first side and the second side are opposite; a first end of the first segment winding is electrically connected to a first end of the second segment winding through a first connecting piece, a second end of the first segment winding is electrically connected to a first pin through a second connecting piece, a second end of the second segment winding forms a second pin, and the first connecting piece and the second connecting piece both pass through the first insulating layer; a second metal winding, foil-wound on the magnetic core, comprising a third segment winding formed on the first wiring layer and a fourth segment winding formed on the second wiring layer, at least part of the third segment winding is located on the second side of the magnetic core, and at least part of the fourth segment winding is located on the first side of the magnetic core; a first end of the third segment winding is connected to a first end of the fourth segment winding through a third connecting piece, and a second end of the fourth segment winding forms a third pin, and the third connecting piece passes through the first insulating layer.

2. The transformer module of claim 1, wherein, At least one of the first connecting piece, the second connecting piece and the third connecting piece is a via hole, or the metal winding connected with the connecting piece is an integral piece formed by cutting and folding the metal winding.

3. The transformer module of claim 1, wherein, A second end of the third segment winding is electrically connected to the first pin.

4. The transformer module of claim 3, wherein, The first pin, the second pin and the third pin are all located on a first face of the transformer module.

5. The transformer module of claim 3, wherein, The magnetic core further comprises a second insulating layer and a third wiring layer, wherein the third wiring layer and the second insulating layer are sequentially arranged between the first insulating layer and the second wiring layer; and A third metal winding, foil-wound on the magnetic core, is located on the third wiring layer.

6. The transformer module of claim 5, wherein, The third pin is a plurality of pins, and the second pin further comprises a plurality of tooth-shaped parts, and the plurality of tooth-shaped parts and the plurality of third pins are arranged alternately.

7. The transformer module of claim 5, wherein, The second pin and the third pin are both a plurality of pins, and the plurality of second pins and the plurality of third pins are arranged alternately.

8. The transformer module of claim 3, wherein, The magnetic core comprises a through hole, wherein the first pin, the second pin and the third pin are all C-shaped or mouth-shaped around the through hole, and the first pin is located between the second pin and the third pin.

9. The transformer module of claim 3, wherein, The magnetic core comprises a through hole, and the first pin, the second pin and the third pin are all a plurality of pins, wherein the plurality of first pins, the plurality of second pins and the plurality of third pins are all arranged around the through hole, and the plurality of first pins are located between the plurality of second pins and the plurality of third pins.

10. The transformer module according to claim 3, wherein a length of the first pin is greater than or equal to 1 / 2 of a length of the first metal winding; and / or a length of the second pin is greater than or equal to 1 / 2 of the length of the first metal winding; and / or The length of the third pin is greater than or equal to 1 / 2 of the length of the first metal winding.

11. The transformer module of claim 3, wherein, the first pin is a plurality, and the total length of the plurality of first pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the second pin is a plurality, and the total length of the plurality of second pins is greater than or equal to 1 / 2 of the length of the first metal winding; and / or, the third pin is a plurality, and the total length of the plurality of third pins is greater than or equal to 1 / 2 of the length of the first metal winding.

12. The transformer module of claim 3, wherein, The first insulating layer comprises a base insulating layer and an auxiliary insulating layer.

13. The transformer module of claim 12, wherein, The base insulating layer is formed by an electroplating process, and the auxiliary insulating layer is a locally arranged insulating glue.

14. A power module, characterized by Comprising: A transformer module according to claim 3, wherein the first pin, the second pin, and the third pin are all located on the first surface of the transformer module. A switch module, the switch module being in contact with the first surface of the transformer module.

15. The power module of claim 14, wherein, The switch module comprises a carrier plate and at least one power switch, the power switch being arranged on the carrier plate, and the power switch being electrically connected with the first pin and / or the second pin.

16. The power module of claim 15, wherein, The power module further comprises: A capacitor module, the capacitor module being arranged on the carrier plate and adjacent to the transformer module, and the capacitor module being electrically connected with the first pin or the second pin; or, The capacitor module is located on the carrier plate and adjacent to the switch module on the same side; or, The capacitor module is embedded in the carrier plate; or, The capacitor module is located in a window of the transformer module; or, The capacitor module is located on the upper surface of the transformer module; or The capacitor module is located below the power switch.

17. The power module of claim 16, wherein, The switch module comprises a plurality of first power switches connected in parallel and a plurality of second power switches connected in parallel, and the plurality of first power switches and the plurality of second power switches are arranged in two separate rows.

18. A method of manufacturing a metal winding in a transformer module, characterized by Comprising: Cutting the first metal foil to form a connecting piece and a pin; Insulating the surface of at least one of the first metal foil and a second metal foil; Bending the first metal foil to form a first metal winding wrapped around a magnetic core; the first metal winding comprises a first segment winding formed on a first wiring layer and a second segment winding formed on a second wiring layer, at least part of the first segment winding is located on a first side of the magnetic core, and at least part of the second segment winding is located on a second side of the magnetic core, the first side and the second side are opposite; Wrapping the second metal foil at least partially on the surface of the first metal winding to form a second metal winding, and the pin of the first metal winding passes through the second metal winding; the second metal winding comprises a third segment winding formed on the first wiring layer and a fourth segment winding formed on the second wiring layer, at least part of the third segment winding is located on the second side of the magnetic core, and at least part of the fourth segment winding is located on the first side of the magnetic core.

19. The manufacturing method according to claim 18, wherein The surface of at least one of the first metal foil and the second metal foil is insulated, including: a first insulation treatment is performed on the surface of the at least one metal foil to form a base insulation layer on the inner side; a second insulation treatment is performed on the metal foil with the base insulation layer to form an auxiliary insulation layer on the outer side.

20. The manufacturing method according to claim 19, wherein The base insulation layer is formed by electroplating.

21. The manufacturing method according to claim 19, wherein The auxiliary insulation layer is a locally arranged insulating glue.

22. The manufacturing method of claim 18, wherein, Before the surface of at least one of the first metal foil and the second metal foil is insulated, the surface of the at least one metal foil is roughened. After the surface of at least one of the first metal foil and the second metal foil is insulated, the surface of the at least one metal foil is coated with an adhesive layer.

23. The manufacturing method according to claim 19, wherein The second metal winding is wound on the surface of the first metal winding, and a via hole or a gap is formed during the winding to allow the pin of the first metal winding to pass through. A third metal foil is cut to form a via hole or a gap, and the third metal foil is bent and wrapped on the surface of the second metal winding to form a third metal winding, and the pin of the first metal winding passes through the via hole or the gap.

24. The manufacturing method according to claim 19, wherein, ​ 25. The production method according to claim 18 or 24, wherein ​

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