Cellular Transformers

This invention relates to matrix transformers, and in particular to matrix

transformers having multiple turn primaries, either single coil windings as for a full
bridge, half bridge or forward converter or multiple coil windings as for push-pull
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windings, split windings or a forward converter having a reset winding.

Figures 1 through 4 show prior art.
Figure 1 shows a magnetic core which may, as an example, not a limitation, be
made of ferrite. Figure 2 shows the core in phantom with a push-pull secondary winding
installed. Figure 3 shows that two of these cores with push pull windings may be used in

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pairs. Figure 4 shows a ten core matrix transformer with a four turn push-pull (eight turn
center-tapped) winding. This requires threading eight wires through the center holes of
the cores. This can be quite difficult, particularly if a good fill factor is needed, as the
wires tend to lay irregularly and cross over each other. Further, the position of the wires
in the hole is random, so optimizing the wire position is difficult if not impossible.

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Figure 5 shows a long, slender insert having therein a plurality of lengthwise

through holes, as shown more particularly in a sectional drawing figure 5a. As an
example, not a limitation, a length of extruded plastic may have nine lengthwise holes.
The walls are preferably thin, to maximize the room available for the wires.
Figure 6 shows a ten core matrix transformer using the inserts. A pair of the

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inserts is inserted into the through holes of the cores. The wires are then threaded
through the holes. Not only are the wires precisely located, the inserts also keep the cores

aligned and can fix their spacing. The inserts may extend somewhat on each end to
provide creepage distance for safety insulation.
With reference to figure two, it can be seen that the secondary winding may
comprise a pair of half helical windings (or, at least the rectangular equivalent of half
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helical windings). In a push pull transformer, it may be desirable to maximize the

coupling of each side of the push-pull winding to the side of the secondary which
conducts current in phase. The primary wires can be threaded through the through holes
that are closest to the in phase secondary winding.
Alternatively, if it is desired to minimize the leakage inductance (maximize the

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coupling) between the halves of the push-pull primary winding, the primary wires for
each side of the push-pull winding can be alternated for maximum interleaving.
Regardless, the transformer is much easier to wind and the winding characteristics
will be much more consistent from transformer to transformer. Also, because each wire
has a precise location and an effective guide, automation of the winding process is

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feasible. Notice that the insert has nine holes, but only eight of them are used. Unused
holes can be left empty. Alternatively, it is possible that a secondary winding could be
wound through all the cores just as the primary winding is. Extra holes can be provided
for such a winding. Note also that more than one wire could be placed in each hole. In
the core and insert of figure 6, a twelve turn push pull (twenty four turn center-tapped)

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winding can be assembled by threading three wires through each hole, either as
individual wires or in a three conductor cable.

Figure 7 shows a matrix transformer core pair each having a short insert with a
plurality of lengthwise through holes. Figure 8 shows that the cores may be placed end
for end with the through holes aligned. If the cores are positioned accurately, the primary
winding may be inserted just as if the inserts were continuous. To ensure alignment,
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coupling sleeves which fit snuggle around protruding extensions of the inserts may be
used.
Figure 9 shows an alternative construction in which the inserts are conductors and
comprise the secondary windings. As an illustration, not a limitation, a winding which is
similar in its external connections to the winding of figure 2 is shown. A first conductive

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insert having lengthwise through holes is connected to the near and far corner
terminations. Below it, a second conductive insert having lenghtwise through holes is
connected to the left and right corner terminations. The two inserts are separated with
insulation.
In this transformer, phasing is important. The side of the primary and the side of

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the secondary which conduct at the same phase must be together. Further, if the primary
winding is used in a configuration that would ordinarily use a single coil, it is preferred
that it be wound as two coils in parallel. For example, if a transformer is to be made with
a full bridge primary winding (normally a single coil) of eight turns, but if the secondary
is a cellular winding as shown in figure 9, eight wires should be placed in each side of the

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secondary winding. The wires are then connected in parallel, observing phasing.
Not only is this transformer easier to wind, it also has very low leakage
inductance and excellent coupling. Dielectric isolation is dependent upon the insulation

on the wires, but double and triple insulated wires are readily available to meet safety
requirements. Because each primary conductor is surrounded by the secondary
conductor, temperature differences will be small and thermal conductivity will be
excellent, allowing the conductors to be used with a very high current density and still
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have a low temperature rise.

Figures 10 through 13 show a transformer core with a single secondary winding
as would be useful for a forward converter or an ac transformer. Figure 10 shows a short
core, for a lower voltage and figure 11 shows a longer core of the same section, for a
higher voltage or, perhaps, a lower frequency, as it has a greater effective core area.

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Figure 12 is an end view showing the through holes, and figure 13 is a section view,
showing the magnetic core and the secondary winding. As an example, not a limitation,
seven through holes are shown. The transformer may be wound with ordinary triple
insulated hook up wire. If a reset winding is required, the transformer may be wound
with coaxial wire, and the outer conductor can be connected as the main primary winding

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and the inner conductor can be used as a reset winding.

Construction of the transformer core and secondary winding is very simple. A
core is placed over the secondary conductor and end caps are attached having suitable
terminations. Surface mount feet are shown, but any termination means may be used.
The magnetic core could be pre-formed and slipped over the secondary insert, or it could

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be wound upon it if it is made of a wound material such as amorphous metal or metal. If

ferrite is used, it could be one large core, as shown, but it may be preferred to use two or
more smaller cores, it being equivalent magnetically.

Figure 14 shows a cross section of an alternative transformer. Through holes

provide for four main primary conductors which are flat ribbon conductors. Optional
small round through holes may be provided for a reset winding.
Figures 15 and 16 show respectively an end view and a section of a similar
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transformer having a push-pull secondary winding. The two halves of the push pull
secondary winding are separated by insulation and have separate terminals. Figure 17
shows a section view of a transformer having a push pull secondary winding with through
holes to accommodated ribbon primary conductors.
Two pages follow the above figures, with sketches of alternative transformers.

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Fig. 17