Integrated communication transformer and manufacturing method thereof

Abstract

The invention belongs to the technical field of transformers, and provides an integrated communication transformer and a manufacturing method thereof.The integrated communication transformer comprises a magnetic core and a PCB coil board; wherein the magnetic core is arranged on the PCB coil board in a penetrating mode, a first copper-clad pin position set and a second copper-clad pin position set are arranged at the two ends of the PCB coil board, the PCB coil board comprises a coil layer and a bottom layer arranged on one side of the coil layer, the coil layer comprises a primary winding and a secondary winding, and the primary winding and the secondary winding are arranged along the winding of the magnetic core. A copper-clad wire is arranged on the surface of the bottom layer, the primary winding is connected with the first copper-clad pin position group through the copper-clad wire, and the secondary winding is connected with the second copper-clad pin position group through the copper-clad wire.

Description

Technical Field

[0001] The present invention belongs to the technical field of transformers, and in particular relates to an integrated communication transformer and a manufacturing method thereof. Background Art

[0002] The statements in this section merely provide background information related to the present invention and do not necessarily constitute prior art.

[0003] Our communications transformers include T1 / E1 isolation transformers; ISDN / ADSL interface transformers; VDSL high-pass / low-pass filter modules and interface transformers; T3 / E3, SDH, and 64KBPS interface transformers; 10 / 100BASE, 1000BASE-TX, 2.5GBASE, 5GBASE, and 10GBASE network transformers; RJ45 integrated ICM transformers; vehicle-mounted BMS signal transformers; vehicle-mounted T-BOX network transformers; and photovoltaic energy storage BMS signal transformers. We also offer custom-designed transformers. Our communications transformers are primarily used in high-performance digital switches; SDH / ATM transmission equipment; ISDN, ADSL, VDSL, and POE powered devices; FILT fiber optic loop equipment; Ethernet switches; BMS communications; vehicle-mounted T-BOXs, and more.

[0004] The communication transformer plays two main roles on a network card: one is to transmit data, and the differential signal sent by PHY is coupled and filtered with a differential mode coupled coil to enhance the signal, and coupled to the other end of the network cable with different voltage levels through electromagnetic field conversion; the other is to isolate the different voltage levels between different network devices connected by the network cable to prevent different voltages from being transmitted through the network cable and damaging the equipment.

[0005] Current communication transformers typically consist of a wound transformer, a common-mode inductor, a plastic base, a plastic cover, and a solder pad bracket. These transformers are wound by winding twisted wire around a closed magnetic core. This makes winding difficult when the number of turns is large, and manual threading can lead to errors in the number of turns. Furthermore, the resulting product has relatively poor consistency and reliability. Summary of the Invention

[0006] To address the above-mentioned issues, the present invention proposes an integrated communications transformer and a manufacturing method thereof. The conventional closed-magnetic-circuit magnetic core coil winding is replaced by a stacked PCB board. The method of winding a twist coil on a magnetic ring is modified to wiring on a PCB board, so as to achieve the effect of integrating each winding coil onto the same PCB board. This achieves a highly integrated and flat transformer, effectively prevents overheating of the transformer, and improves the reliability of the transformer.

[0007] According to some embodiments, a first solution of the present invention provides an integrated communication transformer, which adopts the following technical solution: An integrated communications transformer comprises a magnetic core and a PCB coil board; wherein the magnetic core is arranged through the PCB coil board, a first copper-clad pin group and a second copper-clad pin group are provided at both ends of the PCB coil board, the PCB coil board comprises a coil layer and a bottom layer arranged on one side of the coil layer, the coil layer comprises a primary winding and a secondary winding arranged around the magnetic core, a copper-clad wire is provided on the surface of the bottom layer, the primary winding is connected to the first copper-clad pin group via the copper-clad wire, and the secondary winding is connected to the second copper-clad pin group via the copper-clad wire.

[0008] As a further technical definition, the coil layer includes a first coil layer, a second coil layer and a first copper-clad through-hole group, the primary winding is arranged between the first coil layer and the second coil layer, and the primary winding is connected to the copper-clad wire through the first copper-clad through-hole group.

[0009] As a further technical definition, the coil layer also includes a third coil layer, a fourth coil layer and a second copper-clad through-hole group, the secondary winding is arranged between the third coil layer and the fourth coil layer, and the secondary winding is connected to the copper-clad wire through the second copper-clad through-hole group.

[0010] As a further technical limitation, the integrated communication transformer also includes a base, which is arranged on one side of the PCB coil board, and a groove matching the magnetic core is opened on the base close to the PCB coil board side.

[0011] Furthermore, base openings matching the first copper-clad pin position group and the second copper-clad pin position group are provided on both sides of the base, and connectors for fixing the base and the PCB coil board are provided in the first copper-clad pin position group, the second copper-clad pin position group and the base openings, and the connectors are pins arranged in an L-shaped structure.

[0012] Furthermore, the first copper-clad pin position group and the second copper-clad pin position group are both configured as copper-clad through-holes, and the pins pass through the first copper-clad pin position group and the second copper-clad pin position group and extend out of the PCB coil board.

[0013] Furthermore, the magnetic core includes a first magnetic core and a second magnetic core, the first magnetic core is arranged in a U-shaped structure, and the PCB coil board is provided with a magnetic core through-hole matching the open end of the first magnetic core.

[0014] Furthermore, one end of the second magnetic core is arranged in the groove, and the other end is arranged at the magnetic core through-hole; the open end of the first magnetic core passes through the magnetic core through-hole and is attracted to the second magnetic core.

[0015] As a further technical limitation, bosses are provided on both sides of the PCB coil board, and the first copper-clad pin position group and the second copper-clad pin position group are both provided on the edge of the boss and extend to the edges of both sides of the boss along the thickness direction of the PCB coil board.

[0016] According to some embodiments, a second solution of the present invention provides a method for manufacturing an integrated communication transformer, which is used to manufacture the integrated communication transformer provided by the first solution, using the following technical solutions: A method for manufacturing an integrated communication transformer comprises: providing a magnetic core through-hole matching a magnetic core on a laminated PCB coil board; routing copper wires along the corresponding magnetic core through-holes on each layer of the PCB coil board to form a winding coil; and fixing a first magnetic core to a second magnetic core by gluing through the magnetic core through-holes to obtain an integrated communication transformer.

[0017] Compared with the prior art, the present invention has the following beneficial effects: The present invention replaces the traditional closed magnetic circuit core coil winding method with a laminated PCB board. That is, the method of winding the twist coil on the magnetic ring is modified to wiring on the PCB board, so as to achieve the effect of integrating each winding coil onto the same PCB board, realizing a highly integrated and flat transformer, effectively preventing overheating of the transformer, and improving the reliability of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings constituting a part of the specification of this embodiment are used to provide a further understanding of this embodiment. The schematic embodiments and descriptions of this embodiment are used to explain this embodiment and do not constitute an improper limitation on this embodiment.

[0019] Figure 1 This is a structural diagram of a baseless integrated communication transformer in Embodiment 1 of the present invention; Figure 2 This is a structural diagram of a baseless integrated communication transformer in Embodiment 1 of the present invention; Figure 3 This is a schematic diagram of an exploded structure of a baseless integrated communication transformer in the first embodiment of the present invention; Figure 4 This is a structural diagram of an integrated communication transformer including a base in the second embodiment of the present invention; Figure 5 This is a schematic diagram of an exploded structure of an integrated communication transformer including a base in the second embodiment of the present invention; Figure 6A schematic structural diagram of a base in the second embodiment of the present invention; Figure 7 Schematic diagram of the laminated structure of the PCB coil board in Embodiment 1 or Embodiment 2 of the present invention; Figure 8 This is a structural diagram of an integrated communication transformer with a shared magnetic core in the third embodiment of the present invention; Figure 9 This is a schematic diagram of an exploded structure of an integrated communication transformer with a shared magnetic core in the third embodiment of the present invention; Figure 10 Schematic diagram of the laminated structure of the PCB coil board in the third embodiment of the present invention; Figure 11 This is a structural diagram of an integrated communication transformer with multiple sets of magnetic cores in the fourth embodiment of the present invention; Figure 12 This is a schematic diagram of an exploded structure of an integrated communication transformer with multiple sets of magnetic cores in the fourth embodiment of the present invention; Figure 13 Schematic diagram of the positions of the pins and through holes of the PCB coil board in the first, second or fourth embodiment of the present invention; Figure 14 Schematic diagram of the positions of the pins and through holes of the PCB coil board in the third embodiment of the present invention; Among them, 1. magnetic core; 2. PCB coil board; 3. first copper-clad pin position group; 4. second copper-clad pin position group; 5. copper-clad wire; 6. base; 7. base opening; 8. connector; 9. first magnetic core; 10. second magnetic core; 11. magnetic core through-hole; 12. boss. DETAILED DESCRIPTION

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention belongs.

[0022] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0023] In the present invention, terms such as "upper", "lower", "left", "right", "front", "back", "vertical", "horizontal", "side", "bottom", etc. indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. They are relational words determined only for the convenience of describing the structural relationships of the various parts or elements of the present invention, and do not specifically refer to any part or element in the present invention, and should not be understood as limiting the present invention.

[0024] In the present invention, terms such as "fixed connection," "connected," and "connection" should be interpreted broadly to mean a fixed connection, an integral connection, or a detachable connection; a direct connection or an indirect connection through an intermediary. Relevant researchers or technicians in this field may determine the specific meanings of these terms in the present invention based on specific circumstances, and they should not be construed as limitations of the present invention.

[0025] In the absence of conflict, the embodiments of the present invention and the features thereof may be combined with each other.

[0026] Example 1 The first embodiment of the present invention introduces an integrated communication transformer, wherein the integrated communication transformer does not include a base structure.

[0027] like Figure 1 、 Figure 2 and Figure 3 An integrated communications transformer is shown, comprising a magnetic core 1 and a PCB coil board 2. The magnetic core 1 is disposed throughout the PCB coil board 2, with a first copper-clad pin group 3 and a second copper-clad pin group 4 disposed at both ends of the PCB coil board 2. The PCB coil board 2 comprises a coil layer and a bottom layer disposed on one side of the coil layer. The coil layer comprises a primary winding and a secondary winding disposed along the magnetic core. Copper-clad wires 5 are disposed on the surface of the bottom layer. The primary winding is connected to the first copper-clad pin group 3 via the copper wires 5, and the secondary winding is connected to the second copper-clad pin group 4 via the copper wires 5. In this embodiment, the coil layer comprises a first coil layer, a second coil layer, a first copper-clad through-hole group, a third coil layer, a fourth coil layer, and a second copper-clad through-hole group. The primary winding is disposed between the first and second coil layers, and the secondary winding is disposed between the third and fourth coil layers. The primary winding is connected to the copper wires via the first copper-clad through-hole group, and the secondary winding is connected to the copper wires via the second copper-clad through-hole group.

[0028] It should be noted that if Figure 7 and Figure 13 As shown, in this embodiment, the first copper-clad pin position group 3 is pin ①, pin ② and pin ③; the first copper-clad through hole group is through hole c , through hole h , through hole d and through holes gThe second copper-clad pin group 4 is pin ①, pin ③, pin ④ and pin ⑥; the second copper-clad through hole group is through hole b , through hole e , through hole i and through holes k .

[0029] It should be noted that the structure of the PCB coil board 2 is not specifically shown in the figure. Figure 7 A detailed introduction to the structure of PCB coil board 2 is given. Figure 3 As shown, the magnetic core 1 in this embodiment includes a first magnetic core 9 and a second magnetic core 10. The first magnetic core 9 is arranged in a U-shaped structure, and a magnetic core through-hole 11 matching the open end of the first magnetic core 9 is opened on the PCB coil plate 2; one end of the second magnetic core 10 is arranged at the magnetic core through-hole 11, and the open end of the first magnetic core 9 passes through the magnetic core through-hole 11 and is attracted to the second magnetic core 10.

[0030] like Figure 1 As shown, bosses 12 are provided on both sides of the PCB coil board 2, and the first copper-clad pin position group 3 and the second copper-clad pin position group 4 are both provided at the edge of the boss 12 and extend to the two side edges of the boss 12 along the thickness direction of the PCB coil board 2.

[0031] This embodiment takes the stacked structure of a five-layer PCB board as an example. Figure 7 As shown, expand the detailed introduction: Primary winding coil setup: bottom wiring (① pin) → through hole c → Top layer routing (pin ① and pin ③) → Through hole h →Fourth coil layer / bottom layer wiring (②pin) →Through hole d → Second coil layer wiring (pin ① and pin ③) → Through hole g → Bottom layer wiring (③ pins); Secondary winding coil setup: Fourth coil layer / bottom wiring (4th pin) → through hole b → First coil layer wiring (pin ① and pin ③) → Through hole e →Fourth coil layer / bottom layer wiring →Through hole i → First coil layer wiring (pins 4 and 6) → Through hole k ; Second winding (common mode inductor) setup: Fourth coil layer / bottom layer wiring (5th pin) → through hole a → Third coil layer wiring (pin ① and pin ③) → Through hole f →Fourth coil layer / bottom layer wiring →Through hole j → Third coil layer wiring (pins 4 and 6) → Through hole l →Fourth coil layer / bottom layer wiring (6th pin).

[0032] It should be noted that the wiring between each layer of PB boards and the wiring on each layer of PB boards are all copper-clad.

[0033] Example 2 A second embodiment of the present invention introduces an integrated communication transformer, wherein the integrated communication transformer includes a base structure.

[0034] like Figure 4 、 Figure 5 and Figure 6 An integrated communication transformer shown includes a magnetic core 1, a base 6 and a PCB coil board 2, wherein the base 6 is arranged on one side of the PCB coil board 2, and a groove 12 matching the magnetic core 1 is opened on the base 6 close to the side of the PCB coil board 2. The magnetic core 1 is arranged through the PCB coil board 2, and a first copper-clad pin position group 3 and a second copper-clad pin position group 4 are arranged on both ends of the PCB coil board 2. The PCB coil board 2 includes a coil layer and a bottom layer arranged on one side of the coil layer. The coil layer includes a primary winding and a secondary winding arranged around the magnetic core 1. A copper wire 5 is provided on the surface of the bottom layer. The primary winding is connected to the first copper-clad pin position group through the copper wire, and the secondary winding is connected to the second copper-clad pin position group through the copper wire.

[0035] In this embodiment, the coil layer includes a first coil layer, a second coil layer, a first copper-clad through-hole group, a third coil layer, a fourth coil layer and a second copper-clad through-hole group. The primary winding is arranged between the first coil layer and the second coil layer, and the secondary winding is arranged between the third coil layer and the fourth coil layer. The primary winding is connected to the copper wire 5 through the first copper-clad through-hole group, and the secondary winding is connected to the copper wire 5 through the second copper-clad through-hole group.

[0036] It should be noted that there is no specific diagram of the structural setting of the PCB coil board 2. The detailed description of the structural setting of the PCB coil board 2 is completely consistent with that of the embodiment 1, and will not be repeated here in this embodiment.

[0037] like Figure 5 and Figure 6As shown, base openings 7 matching the first copper-clad pin group 3 and the second copper-clad pin group 4 are provided on both sides of the base 6, and connectors 8 for fixing the base 6 and the PCB coil board 2 are provided in the first copper-clad pin group 3, the second copper-clad pin group 4 and the base openings 7, and the connectors 8 are pins arranged in an L-shaped structure; the first copper-clad pin group 3 and the second copper-clad pin group 4 are both arranged as copper-clad through-holes, and the pins pass through the first copper-clad pin group 3 and the second copper-clad pin group 4 and extend out of the PCB coil board 2; the magnetic core 1 includes a first magnetic core 9 and a second magnetic core 10, and the first magnetic core 9 is arranged in a U-shaped structure, and a magnetic core through-hole 11 matching the open end of the first magnetic core 9 is provided on the PCB coil board 2; one end of the second magnetic core 10 is arranged in the groove 12, and the other end is arranged at the magnetic core through-hole 11; the open end of the first magnetic core 9 passes through the magnetic core through-hole 11 and is attracted to the second magnetic core 10.

[0038] Example 3 The third embodiment of the present invention introduces an integrated communication transformer, wherein the integrated communication transformer is provided with a group of magnetic cores, that is, a shared magnetic core structure is adopted. Figure 8 and Figure 9 The integrated communication transformer shown is different from the integrated communication transformer introduced in Example 1 in that this embodiment adopts a structural setting of a group of magnetic cores 1, that is, a group of magnetic core through-holes 11 are opened on the PCB coil board 2. The other structural settings are consistent with the integrated communication transformer introduced in Example 1, and this embodiment will not be repeated here.

[0039] It should be noted that if Figure 10 and Figure 14 As shown, the first copper-clad pin position group 3 is pin ①, pin ② and pin ③; the first copper-clad through hole group is through hole d , through hole k, through hole e and through holes j ; The second copper-clad pin group 4 is pin ④, pin ⑤ and pin ⑥; the second copper-clad through hole group is through hole c , through hole g , through hole a , through hole h , through hole b , through hole l , through hole f and through holes i .

[0040] This embodiment combines Figure 10 A detailed introduction to the PCB board stacking structure: Primary winding coil setup: Fifth coil layer (pin ①) → through hole d → Top layer wiring → Via k → Fifth coil layer (pin ②) → Via e → Bottom layer wiring → Through hole j→Fifth coil layer (pin ③); Secondary winding coil setup: Fifth coil layer wiring (6th pin) → through hole c → First coil layer wiring → Through hole g →Fifth coil layer wiring→Through hole a → Second coil layer wiring → Through hole h → Fifth coil layer wiring (5th pin) → Through hole b →Third coil layer wiring →Through hole l →Fifth coil layer wiring→Through hole f → Fourth coil layer wiring → through hole i →Fifth coil layer wiring (4th pin).

[0041] Example 4 A fourth embodiment of the present invention introduces an integrated communication network transformer, wherein the integrated communication transformer uses multiple groups of magnetic cores.

[0042] like Figure 11 and Figure 12 The integrated communication transformer shown is different from the integrated communication transformer introduced in Example 1 in that this embodiment adopts a structural setting of multiple groups of magnetic cores, that is, several groups of magnetic core through-holes 11 are opened on the PCB coil board 2, and the laminated structure setting of the PCB coil board 2 corresponding to each group of magnetic cores 1 is exactly the same as that of Example 1, and this embodiment will not be repeated here.

[0043] It should be noted that there is no specific diagram of the structural setting of the PCB coil board 2. The detailed description of the structural setting of the PCB coil board 2 is completely consistent with that of the embodiment 1, and will not be repeated here in this embodiment.

[0044] Example 5 The fifth embodiment of the present invention introduces a method for manufacturing an integrated communication transformer, which is used to manufacture the integrated communication transformers introduced in the first, second, third and fourth embodiments.

[0045] A method for manufacturing an integrated communication transformer comprises: providing a magnetic core through-hole matching a magnetic core on a laminated PCB coil board; routing copper wires along the corresponding magnetic core through-holes on each layer of the PCB coil board to form a winding coil; and fixing a first magnetic core to a second magnetic core by gluing through the magnetic core through-holes to obtain an integrated communication transformer.

[0046] The detailed steps are the same as the working principles of the integrated communication transformer provided in Example 1, Example 2, Example 3, or Example 4, and will not be repeated here.

[0047] Obviously, those skilled in the art may make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if such changes and modifications fall within the scope of the claims and their equivalents, the present invention is intended to include such changes and modifications.

[0048] The above description is merely a preferred embodiment of this embodiment and is not intended to limit this embodiment. Those skilled in the art will readily appreciate that this embodiment may be modified and varied in various ways. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this embodiment shall be within the scope of protection of this embodiment.

Claims

1. An integrated communication transformer, characterized in that: It includes a magnetic core and a PCB coil board; wherein, the magnetic core is arranged through the PCB coil board, and a first copper-clad pin position group and a second copper-clad pin position group are arranged on both ends of the PCB coil board. The PCB coil board includes a coil layer and a bottom layer arranged on one side of the coil layer. The coil layer includes a primary winding and a secondary winding arranged along the magnetic core. The surface of the bottom layer is provided with a copper-clad wire. The primary winding is connected to the first copper-clad pin position group through the copper-clad wire, and the secondary winding is connected to the second copper-clad pin position group through the copper-clad wire.

2. An integrated communication transformer as claimed in claim 1, characterized in that: The coil layer includes a first coil layer, a second coil layer and a first copper-clad through-hole group. The primary winding is arranged between the first coil layer and the second coil layer. The primary winding is connected to the copper-clad wire through the first copper-clad through-hole group.

3. An integrated communication transformer as claimed in claim 1, characterized in that: The coil layer further includes a third coil layer, a fourth coil layer and a second copper-clad through-hole group. The secondary winding is arranged between the third coil layer and the fourth coil layer. The secondary winding is connected to the copper-clad wire through the second copper-clad through-hole group.

4. An integrated communication transformer as claimed in claim 1, characterized in that: It also includes a base, which is arranged on one side of the PCB coil board, and a groove matching the magnetic core is opened on the base close to the PCB coil board side.

5. An integrated communication transformer as claimed in claim 4, characterized in that: Base openings matching the first copper-clad pin position group and the second copper-clad pin position group are provided on both sides of the base. Connectors for fixing the base and the PCB coil board are provided in the first copper-clad pin position group, the second copper-clad pin position group and the base openings. The connectors are pins arranged in an L-shaped structure.

6. An integrated communication transformer as claimed in claim 5, characterized in that: The first copper-clad pin position group and the second copper-clad pin position group are both configured as copper-clad through holes, and the pins penetrate the first copper-clad pin position group and the second copper-clad pin position group and extend out of the PCB coil board.

7. An integrated communication transformer as claimed in claim 4, characterized in that: The magnetic core includes a first magnetic core and a second magnetic core. The first magnetic core is arranged in a U-shaped structure. The PCB coil board is provided with a magnetic core through-hole matching the open end of the first magnetic core.

8. An integrated communication transformer as claimed in claim 7, characterized in that: One end of the second magnetic core is arranged in the groove, and the other end is arranged at the magnetic core through-hole; the open end of the first magnetic core passes through the magnetic core through-hole and is attracted to the second magnetic core.

9. The integrated communication transformer as claimed in claim 1, characterized in that: Bosses are provided on both sides of the PCB coil board. The first copper-clad pin position group and the second copper-clad pin position group are both provided at the edge of the boss and extend to the edges of both sides of the boss along the thickness direction of the PCB coil board.

10. A method for manufacturing an integrated communication transformer, for manufacturing the integrated communication transformer according to any one of claims 1 to 9, characterized in that: A magnetic core through-hole matching the magnetic core is opened on a PCB coil board with a laminated arrangement, and copper wire is routed along the corresponding magnetic core through-hole on each layer of the PCB coil board to form a winding coil. The first magnetic core passes through the magnetic core through-hole and is fixed to the second magnetic core with glue to obtain an integrated communication transformer.

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