Toroidal transformer assembly, and electrical component module assembly

Abstract

To provide an improved toroidal transformer assembly and an electronic component module assembly.SOLUTION: In an electronic component module assembly, a toroidal transformer assembly 24 includes a transformer mounting plate 26 receptive of the toroidal transformer. The transformer mounting plate 26 includes a base 92, a center boss 36 extending from the base 92, and an outer ring 40 extending from the base 92 and separated from the center boss 36. The center boss 36 and the outer ring 40 define a mounting location for a toroidal transformer between the center boss 36 and the outer ring 40. Multiple fins 46 are positioned to conduct thermal energy from the toroidal transformer to the base 92.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] Exemplary embodiments relate to the art of electrical power systems, and more particularly to the assembly, disassembly, and cooling of such systems. [Background technology]

[0002] Power systems, for example, include one or more toroidal transformers as part of a printed wiring board (PWB) assembly. A toroidal transformer is a package that contains a toroidal-shaped magnetic core with conductive windings around the core.

[0003] The nature of the toroidal shape is efficient at keeping the magnetic flux contained, but presents a challenge in removing the heat dissipated in the core and windings. Traditionally, the winding assembly is mounted in contact with a winding chassis or heat sink, which provides thermal contact only within a circle with little surface area for conduction. To prevent damage to the winding(s), the windings must be sized to accommodate worst-case "hot spot" temperatures, increasing the size and weight of the assembly. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, as power densities in such power systems, such as those for space applications, become increasingly high, solutions are needed to adequately cool the components of the power systems. Additionally, it is desirable to improve the modularity of such systems to make them easier to assemble and to disassemble or replace components. [Means for solving the problem]

[0005] In one embodiment, a toroidal transformer assembly of an electronic component module assembly includes a transformer mounting plate capable of receiving a toroidal transformer. The transformer mounting plate includes a base, a central boss extending from the base, and an outer ring extending from the base and separated from the central boss. The central boss and the outer ring define a mounting location for the toroidal transformer between the central boss and the outer ring. A plurality of fins are positioned to conduct thermal energy from the toroidal transformer to the base.

[0006] Additionally or alternatively, in this or other embodiments, a volume of potting material is positioned at the attachment location between the central boss and the outer ring.

[0007] Additionally or alternatively, in this or other embodiments, the volume of potting material substantially covers the toroidal transformer.

[0008] Additionally or alternatively, in this or other embodiments, a plurality of central fins extend radially outward from the central boss and a plurality of inner fins extend radially inward from the outer ring.

[0009] Additionally or alternatively, in this or other embodiments, the toroidal transformer includes a toroidal core and one or more conductive windings wound around the core.

[0010] Additionally or alternatively, in this or other embodiments, a plurality of outer fins extend radially outward from the outer ring.

[0011] In another embodiment, an electrical component module assembly includes a printed wiring board, a first stiffener attached to the printed wiring board, and a toroidal transformer assembly secured to the first stiffener. The toroidal transformer includes a toroidal core and one or more conductive windings wound around the core. A transformer mounting plate is capable of receiving the toroidal transformer. The transformer mounting plate includes a base, a central boss extending from the base, and an outer ring extending from the base and separated from the central boss, the central boss and the outer ring defining a mounting location for the toroidal transformer between the central boss and the outer ring. A plurality of fins are positioned to conduct thermal energy from the toroidal transformer to the base and into the first stiffener.

[0012] Additionally or alternatively, in this or other embodiments, a volume of potting material is positioned at the attachment location between the central boss and the outer ring.

[0013] Additionally or alternatively, in this or other embodiments, the volume of potting material substantially covers the toroidal transformer.

[0014] Additionally or alternatively, in this or other embodiments, a plurality of central fins extend radially outward from the central boss.

[0015] Additionally or alternatively, in this or other embodiments, a plurality of inner fins extend radially inward from the outer ring.

[0016] Additionally or alternatively, in this or other embodiments, a plurality of outer fins extend radially outward from the outer ring.

[0017] Additionally or alternatively, in this or other embodiments, thermal energy is conducted to a wedgelock mounting rail of the first stiffener.

[0018] Additionally or alternatively, in this or other embodiments, an electromagnetic interference gasket is located between the transformer mounting plate and the first stiffener.

[0019] Additionally or alternatively, in this or other embodiments, the second stiffener is assembled to the first stiffener.

[0020] Additionally or alternatively, in this or other embodiments, a second printed wiring board is secured to a second stiffener on the opposite side of the first stiffener.

[0021] Additionally or alternatively, in this or other embodiments, the electromagnetic interference shielding layer is secured to a second stiffener on the toroidal transformer.

[0022] Additionally or alternatively, in this or other embodiments, the stiffener ring extends from the second stiffener toward the transformer mounting plate and is configured to position the second stiffener relative to the toroidal transformer assembly.

[0023] Additionally or alternatively, in this or other embodiments, one or more wedge locks secure the toroidal transformer assembly to the first stiffener.

[0024] Additionally or alternatively, in this or other embodiments, the printed wiring board is permanently bonded to the first stiffener.

[0025] The following description should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numbered alike. [Brief explanation of the drawings]

[0026] [Figure 1] 1 is a perspective view of an embodiment of an electronic component assembly module. [Figure 2] FIG. 2 is a perspective view of a partially disassembled electronic component assembly module. [Figure 3]FIG. 1 is a plan view of an embodiment of a toroidal transformer assembly. [Figure 4] FIG. 1 is a side view of an embodiment of a toroidal transformer assembly. [Figure 5] FIG. 1 is a perspective view of an embodiment of a toroidal transformer assembly. [Figure 6] FIG. 1 is a partial perspective view of an embodiment of an electronic component assembly module. [Figure 7] FIG. 1 is a cross-sectional view of an embodiment of a toroidal transformer assembly. [Figure 8] FIG. 10 illustrates another cross-sectional view of an embodiment of a toroidal transformer assembly. [Figure 9] 1 is a partial cross-sectional view of an embodiment of an electronic component assembly module. [Figure 10] 1 is a cross-sectional view of an embodiment of a transformer mounting plate. [Figure 11] 1 is a schematic diagram of an assembly sequence for an electronic component assembly module. [Figure 12] FIG. 1 is a first diagram of thermal energy conduction from a toroidal transformer. [Figure 13] A second diagram of thermal energy conduction from a toroidal transformer. [Figure 14] FIG. 3 is a third diagram of thermal energy conduction from a toroidal transformer. DETAILED DESCRIPTION OF THE INVENTION

[0027] A detailed description of one or more embodiments of the disclosed apparatus and methods is presented herein by way of example, and not limitation, with reference to the drawings.

[0028] Referring now to FIG. 1 , a perspective view of an electronic component assembly module 10 is shown. The assembly module 10 includes a first printed circuit board (PWB) 12 and a second printed circuit board 14 disposed on an opposite side of a stiffener assembly 16. The stiffener assembly 16 is positioned between and secured to the first PWB 12 and the second PWB 14. The stiffener assembly 16 includes a first stiffener 18 secured to the first PWB 12 and a second stiffener 20 secured to the second PWB 14. The first stiffener 18 and the second stiffener 20 are formed from a highly thermally conductive material such as aluminum or copper. In some embodiments, the connection between each of the PWBs 12, 14 and the respective stiffeners 18, 20 is a permanent bonded connection, for example, via a layer of double-sided adhesive film 22 between each of the PWBs 12, 14 and the respective stiffeners 18, 20. The stiffener assembly 16 further includes a transformer unit 24 disposed between the first stiffener 18 and the second stiffener 20. The stiffener assembly 16 of the first stiffener 18, the second stiffener 20, and the transformer unit 24, together with the first PWB 12 and the second PWB 14, are secured as an assembled module 10 via one or more wedgelocks 58.

[0029] Referring to FIG. 2 , a perspective view of the assembled module 10 is shown, partially disassembled, with the second PWB 14 and second stiffener 20 removed. The transformer unit 24 includes a transformer mounting plate 26 and a toroidal transformer 28 disposed on the transformer mounting plate 26. The toroidal transformer 28 includes a toroidal-shaped magnetic core 30 with one or more conductive windings 32 wound around the core 30. In some embodiments, the toroidal transformer 28 includes one winding 32, while in other embodiments, the toroidal transformer 28 may include two or more windings 32. The windings 32 are formed from a highly conductive material, such as a copper material, while in some embodiments, the core 30 is formed from a ferrite material.

[0030] 3-5, the toroidal transformer 28 and the transformer mounting plate 26 will be described in more detail. The transformer mounting plate 26 is formed from a thermally conductive material, such as copper or aluminum, and includes a mounting location for the toroidal transformer 28 defined by a central boss 36 extending from a first side 38 of a base 92 of the mounting plate 26, and an outer ring 40 extending from the first side 38. When assembled, the toroidal transformer 28 is positioned between the central boss 36 and the outer ring 40. A plurality of central fins 42 extend radially outward from the central boss 36 toward the toroidal transformer 28. Within the outer ring 40, a plurality of inner fins 44 extend radially inward from the outer ring 40 toward the toroidal transformer 28, and a plurality of outer fins 46 extend radially outward from the outer ring 40. Additionally, at a second side 48 of the transformer mounting plate 26 opposite the first side 38, a mounting base plate 50 protrudes from the second side 48. In some embodiments, the mounting base plate 50 has a circular shape, although other embodiments may utilize other shapes. A plurality of lower fins 52 are located on the second side 48 and extend radially outward from the mounting base plate 50.

[0031] The transformer mounting plate 26 further includes mounting fixtures for securing the transformer units 24 to the first stiffeners 18. In the embodiment shown, the mounting fixtures include fastener holes 54 through which fasteners (not shown) extend to secure the transformer units 24 to the first stiffeners 18. The transformer mounting plate 26 further includes plate rails 56 on which wedge locks 58 are mounted.

[0032] Referring now to FIG. 6 , once the toroidal transformer 28 is installed on the transformer mounting plate 26, a volume of potting material 60 is added to the volume inside the outer ring 40 of the transformer mounting plate 26 on which the toroidal transformer 28 is installed. In some embodiments, as shown, the potting material 60 substantially covers the toroidal transformer 28. In some embodiments, the potting material 60 is a commercially available encapsulant such as Stycast 2850, Sylgard 170, or Scotchcast 280. As shown in the cross-sectional view of FIG. 7 , the potting material 60 fills the spaces between adjacent inner fins 44, between the outer ring 40 and the toroidal transformer 28, between adjacent central fins 42, and between the central boss 36 and the toroidal transformer 28.

[0033] 8, a cross-sectional view of the transformer unit 24 installed in the transformer opening 62 of the first stiffener 18 is shown. The transformer mounting plate 26 includes a tapered plate end 64 that is installed in a complementary tapered open end 66 of the transformer opening 62 to locate the transformer unit 24 in the first stiffener 18. Additionally, the first stiffener 18 includes a reinforcing flange 68 upon which a plate flange 70 of the transformer mounting plate 26 rests. In some embodiments, an electromagnetic interference (EMI) gasket 72 is located between the reinforcing flange 68 and the plate flange 70. The EMI gasket 72, formed from, for example, a wire mesh, provides a low impedance path between the transformer mounting plate 26 and the first stiffener 18 and also facilitates electrical coupling between dissimilar metals.

[0034] Referring now to FIG. 9 , a cross-sectional view of a second stiffener 20 installed on the transformer unit 24 / first stiffener 18 assembly is shown. The second stiffener 20 includes a stiffener plate 74 positioned on the transformer unit 24. A stiffener ring 76 is positioned on a first side 78 of the stiffener plate 74 and extends toward the transformer unit 24. The stiffener ring 76 is sized to mate with the outer ring 40 of the transformer mounting plate 26 to position the second stiffener 20 relative to the transformer mounting plate 26. In some embodiments, as shown in FIG. 9 , the diameter of the stiffener ring 76 is smaller than the diameter of the outer ring 40. Positioning the second stiffener 20 through the interface between the stiffener ring 76 and the outer ring 40 further increases the shock and vibration resistance of the assembly. Additionally, in some embodiments, an EMI shielding layer 80 is secured to a second side 82 of the stiffener plate 74 opposite the first side 78. The EMI shielding layer 80 is formed from a thin metallic material that exhibits high eddy current losses in the presence of radio frequencies, i.e., has high radio frequency absorption. Thus, the EMI shielding layer 80 reduces the magnetic field induced in the second PWB 14. The EMI shielding layer 80 is secured to the second side 82 by, for example, a plurality of fasteners 84 that extend through the EMI shielding layer 80 and into the second stiffener 20.

[0035] Referring now to FIG. 10 , a cross-sectional view of the interface between the first PWB 12 and the transformer unit 24 is shown. The first stiffener 18 has been removed for clarity. A layer of thermally conductive material 86 is positioned between the first PWB 12 and the mounting base plate 50 of the transformer mounting plate 26. The thermally conductive material 86 helps reduce the interfacial thermal resistance between the two components, which is a rotating device that helps remove more heat from the toroidal transformer 28. Fasteners 88 extend from the first PWB 12 to the transformer mounting plate 26, e.g., to the central boss 36, securing the first PWB 12 to the transformer unit 24, with the thermally conductive material 86 between the first PWB 12 and the transformer mounting plate 26.

[0036] 11 , a schematic diagram of the assembly sequence for the assembled module 10 is shown. In block 100, the completed transformer unit 24 is installed on the first stiffener 18. In block 102, the EMI shielding layer 80 is installed and secured to the second stiffener 20. In block 104, the first PWB 12 is installed on the first stiffener 18 with the adhesive film 22. In block 106, the second PWB 14 is installed on the second stiffener 20 with the adhesive film 22. Finally, in block 108, the wedge locks 58 are installed on the plate rails 56 and the stiffener rails 90 (shown in FIGS. 13 and 14 ) of the first stiffener 18. However, the assembly sequence illustrated and described herein is merely exemplary, and one skilled in the art will readily appreciate that other sequences may be utilized to assemble the assembled module 10.

[0037] 12-14, heat transfer from the toroidal transformer 28 is shown. As shown in FIG. 12, thermal energy from the toroidal transformer 28 is transferred radially outward to the inner fins 44, from the inner fins 44 to the outer ring 40, and from the outer ring 40 to the outer fins 46. Furthermore, thermal energy is transferred radially inward from the toroidal transformer 28 to the central fin 42 and from the central fin 42 to the central boss 36. Referring now to FIG. 13, thermal energy travels from the fins 42, 44, and 46 to the base 92 and then to the stiffening rail 90 toward the plate rail 56. Both the plate rail 56 and the stiffening rail 90 are in contact with a heat sink (not shown). Therefore, all thermal energy will ultimately flow through the plate rail 56 and the stiffening rail 90 to the heat sink. Referring to FIG. 14, similarly, thermal energy is transferred from the lower fin 52 to the base 92, through the plate rail 56, and to the stiffening rail 90.

[0038] In the disclosed embodiment, the toroidal transformer 28 is mounted within a cavity in the transformer mounting plate 26, which is a metal component separable from the first stiffener 18. The transformer mounting plate 26 includes fins 42, 44, 46, 52 to carry thermal energy away from the toroidal transformer 28, which is then conducted to the stiffener rails 90. This allows the size of the toroidal transformer 28 to be reduced and / or improves its reliability.

[0039] The transformer mounting plate 26 provides multiple conductive heat transfer paths for heat dissipation from the toroidal transformer 28. This helps maintain the temperature of the toroidal transformer 28 below its maximum operating temperature and includes features that improve ease of assembly and disassembly for easy repair, replacement, or upgrade of the toroidal transformer 28. The transformer mounting plate 26 with machined fins and cavities is easy to manufacture using conventional machining techniques. The EMI gasket 72 installed between the first stiffener 18 and the transformer mounting plate 26 provides a low-impedance path between the transformer mounting plate 26 and the first stiffener 18 and also promotes electrical coupling between dissimilar metals. The EMI shielding layer 80 is lossy (absorptive) at radio frequencies. It reduces magnetic fields induced in the printed wiring board 14. The two-PWB assembly configuration shown in FIG. 1 also significantly aids in meeting structural requirements in vibration and shock environments.

[0040] The term "about" is intended to include the degree of error associated with measurement of a particular quantity based on equipment available at the time of filing.

[0041] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that the terms "comprises" and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0042] While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope of the disclosure. Therefore, it is not intended that the disclosure be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the disclosure, but rather that the disclosure will include all embodiments falling within the scope of the appended claims.

Claims

1. 1. A toroidal transformer assembly for an electronic component module assembly, comprising: a transformer mounting plate capable of receiving the toroidal transformer, the transformer mounting plate comprising: With the base, a central boss extending from a first side of the base; an outer ring extending from the first side of the base and separate from the central boss, the central boss and the outer ring defining a mounting location for a toroidal transformer between the central boss and the outer ring; a mounting base plate protruding from a second side of the base opposite the first side; a plurality of fins for conducting thermal energy from the toroidal transformer to the base; a toroidal transformer assembly including:

2. 10. The toroidal transformer assembly of claim 1, further comprising a volume of potting material disposed at said attachment location between said central boss and said outer ring.

3. 3. The toroidal transformer assembly of claim 2, wherein the volume of potting material substantially covers the toroidal transformer.

4. 2. The toroidal transformer assembly of claim 1, wherein a plurality of central fins extend radially outward from said central boss and a plurality of inner fins extend radially inward from said outer ring.

5. The toroidal transformer comprises: A toroidal core and one or more conductive windings wound around the core; 10. The toroidal transformer assembly of claim 1, comprising:

6. 10. The toroidal transformer of claim 1, wherein a plurality of outer fins extend radially outward from the outer ring.

7. 1. An electrical component module assembly comprising: A printed wiring board; a first reinforcing member attached to the printed wiring board and forming a lattice-shaped frame; a toroidal transformer assembly secured within one of the grid frames of the first stiffener, the toroidal transformer assembly comprising: A toroidal transformer, A toroidal core and one or more conductive windings wound around the core; a transformer mounting plate capable of receiving the toroidal transformer, the transformer mounting plate comprising: With the base, a central boss extending from a first side of the base; an outer ring extending from the first side of the base and separate from the central boss, the central boss and the outer ring defining a mounting location for the toroidal transformer between the central boss and the outer ring; a mounting base plate protruding from a second side of the base opposite the first side; a plurality of fins for conducting thermal energy from the toroidal transformer to the base and into the first stiffener; an electrical component module assembly including:

8. 8. The electrical component module assembly of claim 7, further comprising a volume of potting material disposed at an attachment location between said central boss and said outer ring.

9. 9. The electrical component module assembly of claim 8, wherein the volume of potting material substantially covers the toroidal transformer.

10. The electrical component module assembly of claim 7 , wherein a plurality of central fins extend radially outward from said central boss.

11. The electrical component module assembly of claim 7 , wherein a plurality of inner fins extend radially inward from said outer ring.

12. The electrical component module assembly of claim 7 , wherein a plurality of outer fins extend radially outward from said outer ring.

13. The electrical component module assembly of claim 7 further comprising an electromagnetic interference shield disposed between said transformer mounting plate and said first stiffener.

14. 8. The electrical component module assembly of claim 7, further comprising a second stiffener assembled to said first stiffener, said second stiffener comprising a lattice frame attached to said first stiffener and a stiffener plate disposed within a frame of said lattice frame in which said toroidal transformer is located.

15. 15. The electrical component module assembly of claim 14, further comprising a second printed wiring board secured to said second stiffener opposite said first stiffener.

16. 15. The electrical component module assembly of claim 14, further comprising an electromagnetic interference shielding layer secured onto the stiffener plate of the second stiffener over the toroidal transformer.

17. 15. The electrical component module assembly of claim 14, further comprising a stiffener ring extending from the second stiffener toward the transformer mounting plate configured to position the second stiffener relative to the toroidal transformer assembly.

18. The electrical component module assembly of claim 14 wherein said printed wiring board is permanently bonded to said first stiffener.

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