Transformer with divided primary

Claim 2

A transformer having a core with at least three limbs of equal height connected by yoke means at both ends thereof to define a pair of windows, first winding means which is divided into two separate windings each of which is disposed on a separate limb of said core and at least one second winding means on the third limb which is affected by the sum of the flux lines generated by said first winding means, the height of the core being smaller than the width of the limb carrying said second winding, the cross-sectional shape of the limbs carrying said first winding means being approximately square, comprising the improvement of means for effecting a flux density in said third limb greater than the flux density in each of said separate limbs, said means consisting of the cross-sectional area of the limb carrying said second winding being 25% to 30% smaller than the sum of the cross-sectional areas of the separate limbs carrying said first winding means whereby when said first winding means are the primary windings for said transformer and are connected so that the magnetic flux lines in each of said outer legs which flow into said intermediate leg are added in said intermediate leg, the flux density in said third limb is greater than the flux density in each of said limbs carrying said first windings and whereby said first windings are dimensioned according to the energy transformable in the volume of the limbs carrying them.

Claim 3

The transformer of claim 1, wherein a winding free spacing is provided between each of said windings and said yokes; and including a plurality of bobbins made from light heat conductive plastic material, each of said bobbins having a flange and a holding structure having a plurality of contact pins thereon, the cross-sectional thickness of said flange filling in said winding free space between said windings and said yokes.

Claim 4

The transformer according to claim 2, including a support affixed to at least one of said flanges of at least one of said bobbins, said support having a flat surface in a spaced apart parallel relationship with an opposed flat surface on said holding structure, said opposed surfaces on said support and said holding structure engaging opposite side surfaces of at least one of said yoke means.

Claim 5

The transformer according to claim 3, wherein said flanges of each of said bobbins have a plurality of small noses which lay in the same plane as said flanges.

Claim 6

The transformer according to claim 3, wherein at least one of said holding structures has at least one side with a plurality of grooves therethrough, said grooves adapted to guide the ends of said windings to said contact pins.

Claim 7

The transformer according to claim 2, wherein said contact pins project perpendicularly outward and away from said one side of said holding structure.

Claim 8

The transformer according to claim 6, including a heat conductive potting material having a plurality of cooling grooves therein, said potting material completely surrounding said transformer with the ends of said contact pins projecting from said one side terminating outside said potting material.

Claim 9

The transformer of claim 1, wherein the width of the space between adjacent limbs in each window is approximately equal to the width of each of the limbs carrying said first winding means.

Claim 10

The transformer of claim 1, wherein said core consists of laminates.

Claim 11

The transformer of claim 1, wherein adjacent windings on said limbs are wound in an opposite rotational direction.

Claim 12

A transformer construction, comprising: a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate first and second winding means electrically connected together, only said first winding means being wound only on said first outer leg and only said second winding means being wound only on said second outer leg; and a single third winding means wound only on said intermediate leg portion, said first and second winding means being wound in such a sense that the power flux generated by said first and second winding means are added in said intermediate leg, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to less than 2 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions whereby the flux density in said intermediate leg produced by said power flux generated by said first and second winding means is greater than the flux density in each of said first and second outer legs and each of said first and second winding means being dimensioned according to the energy transformable in the volume of the respective one of said first and second outer legs on which they are wound.

Claim 13

A transformer construction, comprising: a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate first and second winding means electrically connected together, only said first winding means being wound only on said first outer leg and only said second winding means being wound only on said second outer leg; and a single third winding means wound only on said intermediate leg portion, said first and second winding means being wound in such a sense that the power flux generated by said first and second winding means are added in said intermediate leg, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to less than 2 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions whereby the flux density in said intermediate leg produced by said power flux generated by said first and second winding means is greater than the flux density in each of said first and second outer legs and each of said first and second winding means being dimensioned according to the energy transformable in the volume of the respective one of said first and second outer legs on which they are wound.

Claim 14

A transformer construction according to claim 11, wherein the total weight of said transformer is in the range of up to and including 0.5 kg. to thereby facilitate its use on a printed circuit board.

Claim 15

A transformer construction, comprising: a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate single first and second windings electrically connected together, only said single first winding being wound only on said first outer leg and only said single second winding being wound only on said second outer leg; and a single third winding wound only on said intermediate leg portion, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to 1.5 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions, said first and second windings being wound in such a sense that the power fluxes generated by them in each of said outer legs flows into said intermediate leg are added in said intermediate leg, the flux density in said intermediate leg produced by said first and second windings being greater than the flux density in each of said first and second outer legs and each of said first and second winding means being dimensioned according to the energy transformable in the volume of the respective one of said first and second outer legs on which they are wound whereby said energy transformed into said first and second outer legs will be less than saturation and whereby the extra heat generated in said intermediate leg, due to the purposeful small construction thereof, tends to be dissipated into the cooler first and second outer legs.

Claim 16

A transformer construction, comprising: a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate single first and second windings electrically connected together, only said single first winding being wound only on said first outer leg and only said single second winding being wound only on said second outer leg; and a single third winding wound only on said intermediate leg portion, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to 1.5 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions, said first and second windings being wound in such a sense that the power fluxes generated by them in each of said outer legs flows into said intermediate leg are added in said intermediate leg, the flux density in said intermediate leg produced by said first and second windings being greater than the flux density in each of said first and second outer legs and each of said first and second winding means being dimensioned according to the energy transformable in the volume of the respective one of said first and second outer legs on which they are wound whereby said energy transformed into said first and second outer legs will be less than saturation and whereby the extra heat generated in said intermediate leg, due to the purposeful small construction thereof, tends to be dissipated into the cooler first and second outer legs.

Claim 17

A transformer construction, comprising: means defining a source of electrical energy; a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate first and second winding means electrically connected together, only said single first winding means being wound only on said first outer leg and only said single second winding means being wound only on said second outer leg; and a single third winding means wound only on said intermediate leg portion, said first and second winding means being connected to said source of electrical energy to produce magnetic flux lines in each of said outer legs which flow into said intermediate leg and which are added in said intermediate leg whereby said third winding means defines a secondary winding and said first and second winding means define a primary winding, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to less than 2 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions whereby the flux density in said intermediate leg produced by said first and second winding means is greater than the flux density in each of said first and second outer legs and each of said first and second winding means being dimensioned according to the energy transformable in the volume of the respective one of said first and second outer legs on which they are wound.

Claim 18

A transformer construction, comprising: means defining a source of electrical energy; a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate first and second winding means electrically connected together, only said single first winding means being wound only on said first outer leg and only said single second winding means being wound only on said second outer leg; and a single third winding means wound only on said intermediate leg portion, said first and second winding means being connected to said source of electrical energy to produce magnetic flux lines in each of said outer legs which flow into said intermediate leg and which are added in said intermediate leg whereby said third winding means defines a secondary winding and said first and second winding means define a primary winding, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to less than 2 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions whereby the flux density in said intermediate leg produced by said first and second winding means is greater than the flux density in each of said first and second outer legs and each of said first and second winding means being dimensioned according to the energy transformable in the volume of the respective one of said first and second outer legs on which they are wound.

Claim 19

A transformer construction, comprising: a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate first and second winding means electrically connected together, only said first winding means being wound only on said first outer leg and only said second winding means being wound only on said second outer leg, each of said first and second winding means being dimensioned according to the energy transformable in the volume of the core material of the respective one of said first and second outer legs on which they are wound and thereby defining primary windings for said transformer construction; and a single third winding means wound only on said intermediate leg portion, said first and second winding means being additionally wound in such a sense that the power flux generated by said first and second winding means are added in said intermediate leg, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to less than 2 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions, the power flux generated by said first and second winding means added in said intermediate leg producing a flux density in said intermediate leg which is greater than the flux density in each of said first and second outer legs, said third winding means defining a secondary winding for said transformer construction.

Claim 20

A transformer construction, comprising: a magnetic core including first and second outer leg portions, an intermediate leg portion and yoke portions connecting the ends of said leg portions to define two substantially rectangular windows; separate first and second winding means electrically connected together, only said first winding means being wound only on said first outer leg and only said second winding means being wound only on said second outer leg, each of said first and second winding means being dimensioned according to the energy transformable in the volume of the core material of the respective one of said first and second outer legs on which they are wound and thereby defining primary windings for said transformer construction; and a single third winding means wound only on said intermediate leg portion, said first and second winding means being additionally wound in such a sense that the power flux generated by said first and second winding means are added in said intermediate leg, means for effecting a flux density in said intermediate leg greater than the flux density in each of said first and second outer legs, said means consisting of the cross-sectional area of said intermediate leg portion of said magnetic core being in the range of from 1.4 to less than 2 times the cross-sectional area of each of the cross-sectional areas of said first and second outer leg portions, the power flux generated by said first and second winding means added in said intermediate leg producing a flux density in said intermediate leg which is greater than the flux density in each of said first and second outer legs, said third winding means defining a secondary winding for said transformer construction.