CA2150953C - Flexible transformer apparatus particularly adapted for high voltage operation - Google Patents

Abstract

A transformer secondary winding comprises a laminated structure which includes first and second outer sheets (11, 13) fabricated from an insulator material, sandwiched between the outer sheets is a thin flexible sheet (12) of a magnetizable material. The first and second outer sheets each have a parallel conductive line pattern on a surface thereof. Selected ends of the lines on the first sheet are connected to the selected ends of the lines on the second sheet in such a manner as to provide a coiled pattern between the sheets, which coiled pattern encircles the central magnetizable sheet. The above laminated configuration can be flexed or rolled into a circular configuration to form a transformer secondary winding. The circular secondary windings are concentrically positioned about a first primary cylinder (70) fabricated from an insulator sheet having parallel conductor elements (125, 126, 127, and 129) arranged on a surface thereof. A second outer primary cylinder (79) surrounds the secondary windings at the outer periphery and is fabricated from an insulator sheet having a conductive line pattern (100, 101, 102) on a surface. The conductive lines of the first and second cylinders are connected to form a primary winding about the secondary windings to provide many different transformer configurations.

Description

wo 94/14174 2 1 ~ O 9 ~ 3 K~/US93/1191~
FLEXIBEETRANSFQRMEl~APPAiR~TllS PARTICULARl,Y
ADAPT~n FOR ~ H VQLTAGEOPERATION
The subject matter of this invention is in part contained in a Disclosure Document No, 317330 filed with the United SLates Patent Office on September 21, 1992.
S TP~hni~ ield of the I
This invention relates to a lldll~ru~ apparaLus in general and more particularly to a flexible Lld"~ru-l~ apparatus which is particularly adapted for use as a fiyback Ll~ ru~ l as those employed in television seLs.
B~ d Art Tl.~ rull~ are utilized in a wide variety of,~ A flyback ll~"~ro""~, is a device which is used to generate a high voltage as is employed in TV
receivers and o~rillocropP~ for biasing Lhe caLhode ray tube or CRT. These Lldllarull~lcl~ produce relatively large voltages at relativeiy small currents. The ability lO produce a large voltage resides in Lhe number of tums that are associated with the secondary winding, as compared to Lhe number of Lums associated with Lhe primarywinding. As is well known, the tums of the secondary, as compared to the turns of Lhe primar~, determine Lhe volLage step up of the L,d"~r.,l,.l.l. Such flybaci transfommers can operate as tuned L.~nsru""~l~ which consist of a primary winding and a number of secondary windings which are runed or resonated. These secondarywindings are wound on the same bobbin and each adjacent secondary windings are connected in series through a diode. This type of flyback Lldll~ru.lll.l is referred to as a tuning flyback transfommer where a horizontal output pulse or flyback pulse is applied as an input pulse to the tuned primary winding.
Anodd order higher ilammonic waveofa r",.,~- ", .IIAI frequency applied to the primary winding, such as for example, the third hammonic is Luned and provided at the secondary winding, based on the disLributed capacity of the secondary windin~
which is small. In this maMer the Lldll~ru~ .. provides a high vol e at the output of the secondary winding. As indicated, such Lldllarul~ a are well known. Many such lldllafullll~ls utilize a toroid or core of a donut shape fabricated from a magnetic material of a given y~ biliLy, which core can be wound with wire. In the ideal core, the winding represents a uniform current sheath circulating about the core in appropriate planes. In this ideal case, the magnetic field is entirely conf~ned within the core, the magnetic field lines are concentric circles and each links with the entire current volume. Such a uniform distributed current flow around the core results in a leakage free configuration. However, this is not the case in practical applications.
Other Lldllarullllcla utili2e cores which are square shaped having multiple le~s. Both the primary and secondary windings rest on one leg. Thus thecurrent distribution around the core is by no means uniform. Ieading to a cenainamount of leakage flux. Such ~:u~ ,.lLiolldl ildllarUllllC. features typically provide leakage flux in the order of 6%, a frequency response in the ranges between 30 Hz and 28 kH2. The efficiency of such Lld.larul-ll.ls is on the order of 85% with the voltage regulation being about 1.5 - 2 megohms. The si2e, both of the toroid and in these E-shaped Lldllarullll~la is bulky and the material is not fully or optimumly utili2ed. The winding employs solid round wires and coupling to the core is not really ideal, leading to local leakage.
As the prior an can ascenain, when such Lldllarulll.~,.a are used as flyback L.dllarull.l.. a they can provide relatively high voltages ranging from 7 - 28 KV
and higher. In any event, the high voltage regulation is poor. If the high voltage regulation is poor, the ~yludu~,d picture of a TV receiver can suffer deterioration.
The prior art was aware of this, and provided certain solutions involving using multi-layer winding flyback LldllarOllll~la which were designed to operate to provide more stable high voltage regulation. The multi-layer winding flyback Lldllarullll~l has been described in many U.S. patents. The problems with these L~dl~arul lll.la relate to shon circuit operation where if a short circuit occurs on a secondary winding, or if discharge is caused within the picture tube, the diodes associated with such transformers are subjec=d to high reverse voltages which can operate to destroy these diodes.

wo 94114174 21~ ~ 9 ~ 3 PCT/US93111919 The prior an is replete with a number of patents which describe various flyback lldll~rul..~ . See U.S. Patent No. 3,866,0~6entitled "Flyback Transforrner Apparatus" issued on l~ebruary 11, 1975 to Miyoshi, et al. This describes a flyback L-d-~rull~ where the primary winding is inductively coupled with the high voltage side winding portion of the first secondary winding. The transformer provides anoutput impedance which is reduced and a focusing voltage which is relatively regulaLed.
U.S. Patent No. 3,904,928 entitled "Flyback T.d.~ro.. " issued on September 9, 1975 to Sawada, et al. This patent describes a flyback transformer which utilizes a magnetic core with secondary windings wound around the core anda primary winding. In this transformer the secondary winding is divided into a plurality of winding units which are alternately connected with the same number of rectifying elements such as diodes in series. The structure is such that a relatively compact device can be :Irrr~mmr~ tp~l, U.S.Patent No. 4,204 7t~ nti~1~ d "FlybackTransforrner" issued on May 20,1983 to Onoue. This patent describes a flyback lldll~rull~ having a plurality of secondary windings wound about a magnetic core. The secondary windings are divided into a plurality of coil units and are alternately connected in series with a plurality of rectifyin~ diodes. The coil urlits are wound around individual layer bobbins where the bobbins are assembled in layers and fitted alternately with the outermost bobbin being mounted with a support in which a plurality of diodes arefixed. The strucLure purpons to be relatively compact.
U.S. Patent No. 4,229,786entitled "Flyback Transformer With A Low Ringing Ratio" issued on October 21,1980 to Mitani, et al. This patent describes a flyback transformer having a teniary winding for obLaining a secondary power source which is wound in a position where the coupling with the primary winding is weak and where the winding interlinks the leakage flux of Lhe secondary winding with the primary winding. The output of the tertiary winding is rectified during the horizonLal WO 94114174 PCT~lS93/11919 2~50953 4 scanning period of a television receiver. In this maMer the wave crest of the ringing is made smaller rer~ardless of the pulse which is applied to the secondary winding.
U.S. Patent No. 4,266,269entitled "Flyback~r.d.,arulll.., " issued on May 5, 1981 to Toba. This describes a multilayer flyback ~.~ulsfu.ll..,l which has flve cylindrical bobbins which are concentrically arranged. A magnetic core is inserted in the first or innermost bobbin and a primary winding is wound in layers on the outer periphery of the bobbin. Diodes are connected between the secondary windings anda capacitor is formed between the cathode of the diode and the anode of another diode. In this manner the l,d. arollll,l is capable of providing high voltage operation in a relatively compact design.
U.S. Patent No. 4,639,706 entitled "Flyback Tlal"fu.~ " issued on Januar,v 27,1986 to Shimizua. This patent describes a flyback ~IdllarOIIII~I where a tertiary coil is wound on an auxiliary bobbin which is separately provided. The bobbin is inserted on a low tension coil bobbin for the primary coil which serves to insulate the tertiary coil from the primary coil.
U.S. Patent No. 5,122,947 entitled "Flyback Transformer Having Coil Al~ Capable of Reducing Leakage of Magnetic Flux" issued on June 16, 1992 to Hishiki. This patent describes a flyback ll~llsf~n..l~l which uses a magnetic core assembly formed by joining a pair of first and second U-shaped core halves each having two leg portions with end surfaces respectively joined in a mutually abutting ~o,.r.~ There are gap spacers interposed between the first and second core parts and a coil is wound about the core parts. The resulting ~lallar~,.",~l has an output winding, which is a secondary, which can be divided into at least two windings to provide separate flux paths.
As one can ascertain, apart from the above-noted patents there exists many more pâtents which involve various Lldllaro"-l~ r~ "~ and which attempt to reduce the size of the lldllarUIlll~,l while making the ~ r~,l".~la more efficieM. For examples of such prior art, reference is made to U.S. Patent No.
4,103,267issued on July 25, 1978 to Olschewski entitled "Hybrid Transformer Device" .

wo 94114174 21~ 0 9 ~ 3 PCT/US93111919 This patent describes a Lla--~ru,--,~l mounted on a ceramic substrate having a plurality of planar conductors formed on a surface of the substrate. The conductors extendradially from an imaginary point on the substrate. A layer of dielectrjc material is formed over the major portions of each of the conductors to form a ring of dielectric S material to which is ferrite toroidal core is secured. The core is precoated with an il~sulating material prior to adhesively being secured to the dielectric ring. A plurality of wire conductors are wire bonded al each end to the exposed ends of the metal conductors on a substrate to form a printed circuit l,d.,~ro,ll,~, U.S. Patent 4,524,342issued on June 18, 1985 to Joseph Mas and is entitled "Toroidal Core El~l,llullla~ Device". This patent describes an Cl~.,llUIll..~ iC device which can include a l,a.,~ru""~. and has a ma~netic core and a segmented electrical winding. The core has an enclosed trunk deftning a central opening. At least three coil sections of the electrical winding ~ncircle the trunk and are ~ uulllr~ idlly spaced about the periphery of the core.
U.S.Patent 4,724,603issued on February 16,1988 to Blanpain et al. and is entitled ~Process for Producing a Toroidal Winding of Small Dimensions and Optimum Geometry". This patent describes an process to produce a small toroid.
Windings having turns which are radial with respect to a cylinder are employed. The cyiinder is provided with slots arranged along the axes of an internal and external cylinder. Hairpin shaped conductive wires are introduced into these slots and welded to one another.
As one can also ascertain, there are many other patents which essentially describe improved magnetic circuits used for small compact ~la.l~ru-as well as for flyback transformers.
The present invention describes a fiexible lldl-~r~"",.l which operates without cu.,~ al wires and is capable of improved operation in providing a reduced leaicage flux, a higher frequency response~ improved efficiency, improved voltage regulation while providing a compact and efficient design.

WO 94/14174 ~ pcTn~ss3lll9l9 2~09~3 6 Disclosure of the Invention A ~ fu~l.l secondary winding comprising a flexible laminated member, comprising a first planar sheet member having a flrst plurality of parallel conductive lines on a surface thereof, a second planar sheet member having a second plurality of parallel conductive lines of a surface thereof, a central planar sheet member fabricated from a rn~vnPti7:1hle material interposed between said first and second planar members and means for coMecting ends of said first and second parallel lines to one another to form a coiled pattern directed about said central member to enable any current flowing in said coiled pattern to magnetize said central planar sheet according to said current flow.
Urief Description of the Drawin~s For a better ",.~ of the present invention, reference is made to the following description of an exemplary ....t,.~.l;,....,l thereof, considered in ~,-; with the accu~ drawings, in which:
FIG. I is a perspective plan view of a composite lamina flexible L~dllarullll~l element according to this invention;
FIG. 2 is a top plan view of a top planar member utilized in this invention;
FIG. 3 is a top plan view of a bottom planar member utilized in this invention;
FIG. 4 is a ~ iVv view of an alternate rl.. l.O.l;.. l showing a planar ~,I.r.~,J~.ti~ which can be employed with this invention;
FIG. 5 is a cross-sectional view showing an .IIlallg~ llL of the planar lld-~rul-l-~,l configuration according to this invention;
FIG. 6 is a cross-sectional view depicting a method of coMecting planar members according to this invention;
FIG. 7 is a top plan view showing an aMular or closed ring cnnfi~llt~tinn of a IIJnar~ fabricated according to this invention;

WO 94/14174 21~ 0 g 5 3 PCT/US93/11919 FIG. 8 is a top view showing a spiral Ll_llarul~ configuralion fabricated according to this invention;
FIG. 9 is a perspective plan view of a flexible primary planar sheet used as an inner cylindrical primary structure;
S FIG. 10 is a perspective plan view of a flexible primary planar sheet used as an outer cylindrical primary structure;
FIG. 11 is a top view depicting the connection between the inner and outer primary structures;
FIG. 12 is a top plan view of a primary cap connector;
FIG. 13 is a cross-sectional view of a ~ rulll~C-l with lop and bottom primary cap . ~ ., ., ,. l~ ~, ~
FIG. 14 is a schematic of an altemate ~ld",ru....~l configuration;
FIG. 15 is a schematic of a ~ rullll~l configuration according to FIG .
14;
FIG. 16 is a circuit diagram depicting an equivalent circuit for the transfommer ~onfi~llr~finn shown in FIG. 7; and FIG. 17 is a circuit diagram depicting the circuit configuration utilized for the Ll_lla[ull.l~ uu..r,~u,d~io,l shown in FIG. 8.

Best Mode for CarrYino Out the Invention Referring to FIG. 1 there is shown a composite planar member 10 which essentially constitutes the main aspect of a secondary winding structure used with the present llalla~ullll~l. The composite ~ rullll._l winding 10 comprises lamina, thin sheets, or insulator tapes A~cllllllllf\~1Al;ll~ conductive parallel line pattems and where a IIIA~ sheet is aAlldwicl~c~ between two conductive line carrier sheets or tapes. The member 10 consists of three sheets and is shown in FIG. 1 in a laminated ~:UI~LlU.liull. The three sheets are extremely thin and the entire composite member 10 can be rolled or otherwise bent and as such is a flexible member. The utilization WO 94/14~74 . . PCTiUS93/11919 2~09~3 8 of the composite laminated nlember 10 will enable one to construct various transforrner ~u~.rl~ l.,,a;.,..c as those of a closed-ring collri~,l.c,Liull or a spiral ,ulif ~ Liu~l.
As seen in FIG. 1, a first planar member 11 is fabricated from an insulating material which, for example, may be a suitable paper such as a Kaptonpaper or some other paper or plastic which is normally used in the integrated circuit field or for with lldllaru~ .a. The insulating material must be able to ~rrr,mmr,r~F
metal deposition or ~v~.oldLiùl~. Disposed upon a top surface of the sheet 11 is a series of conductor elements or conductive lines such as 20, 21, 22 and so on. There are a plurality of such conductive lines 20, 21.. etc.,each of which is parallel to a adjacent ones. The conductor line pattern is directed across the top surface of the insulating sheet 11. Each conductor is formed from a suitable conducting metal such as copper, gold. silver, which is evaporated on the surface of the insulating sheet 11 bycu--v~,.-Liu--~ v~tJuldlio~l techniques using l,l.ulo~ procedures similar to those used in the formation of integrated circuits. In this manner a conductive metal can be evaporated or otherwise positioned on the top surface of the Kapton sheet 11 to forrn the conductor pattern as shown in FIG. 1. Each conductor may be at a slight angle with respect to the Yertical or may be relatively vertical. The conductors are spaced apart by a t,-~ t~ , . .i. .F J fixed distance. The distance between conductors can be extremely small as less than 2.0 mils. The iùsulator sheet 11, as indicated, is relatively thin and may be formed from a paper or other plastic or insulating material having a thickness of dtJ~JI. '.y I mil. The width of a conductor is typically about 5 mils or less.
While suitable metal conductors, such as 20 and 21, can be applied to such substrates by cv.~tJuldlioll techniques or by RF sputtering, they can also be deposited as a paste-like organic, metal glass mixture which are referred to as inks or pastes and are utili~ed in the thick film IC field. In this manner such conductors are applied as a paste-like organic metal glass mixrure to a suitable paper or fiexible plastic substrate. The metals used for thick film conductors are noble metals such as 2l~ass3 platinum, pallad;um, gold, silver and various CUIIIb;lh~iUI~ and alloys of these metals.
To control adhesion, solderability and chemical stability, the glass/metal ratio, particle size and shape of the metals and various culll~ull~ are all irnportant variables.
Thus, it is well known how to impose conductor patterns on a paper or a flexibleplastic substrate to form the planar member 11.
Also shown in FIG. 1 is a planar member 13 which essentially is of the same thickness and material as member 11 and which includes an alternate series of parallel conductors or conductive lines, such as 23, 24 and 25, shown in dashed line in FIG. 1. The surface ~ of planar member 11 and planar member 13 are shown It~ y in FIGS. 2 and 3. Each of the conductor elements, such as 20 and 21 on sheet 11, are coMected to an associated conductor element on the back planar sheet member 13, such as conductor elements 23 and 24. This can be d~,~,ulll~ ll.,d in a number of ways. Shown in FIG. I are apertures 30, 33, 32, 34 and 35 and so on. These apertures are via apertures and enable the top terminal 30, for example, of conductor 20 to be coMected to the top terminal of conductor 23 on substrate 13 via the holes 30 and 30b as shown. In this maMer one forrns an alternating pattern of coMected conductor lines which essentially serve to surround the cenoer member 12. The connected conductive lines form a coil of a zig-zag ,~ pattern disposed about the center planar ,.,.. ~ l/lr sheet 12. The center member 12 is formed from a ~ material and essentially is a magnetic sheet. The center member 12 may consist of a soft iron sheet bounded on both sides by the insulator sheets 11 and 13. The via holes as 30, which coMect the conductors on the planar sheçtl ll to the conductors on planar sheet 13 are not directed through the soft iron central layer 12. This is ~ ,ul~ly shown in FIG. S where reference numeral 50 depicts a layer such as layer 13, reference numeral 52 depicts a layer such as layer Il with the layers separated by the .l,c,... I;,_l,lc layer 51. There are conductors 53 and 54 directed through suitable apertures from the layer 50 to the layer 5~ without in any maMer touching the layer 51. It is of course known that other techniques for joining the members can be ;~ .,...,r. ~i as will be explained.

215û953 `

As one can see from FIG. 1, the basic L~ ru~ secondary winding cnnfi~,rdrion consists of a composite laminar structure which is flexible, consisting of a first planar sheet member 11 having parallel conductors or conductive lines on a top surface thereof. A second planar member 13 has ~ul~ ùlldi~ conductor elements on the top surface thereof and selected end points of the conductive lines on member 11 are joined with end points of the conductive lines on member 13 to form a wireless rul-ll.,l winding dl l~ with the conductors interlaced, insulated and alternating about the magnetic material or magnetic central sheet 12. The connected conductive lines form a zig-zag coiled pattern and operate and function as "windings"
about the "core"as sheet 12. The outer planar sheet members 11 and 13 are referred to as current sheets because this is where the current is directed, while the inner magnetic member 12 is referred to as a magnetic sheet. As one can ascertain, thestructure alternates from the planar member 11 to the planar member 13 via the ollu~",L~d conductive lines, as 20, 23, 21, 24 and so on. In this manner the line structures are associated with the central l.. ~ material sheet 12 and thus form a coil about the center sheet 12.
While the magnetic planar sheet 12 can be fabricated from a soft iron which can be flattened by many ~U~ ,.ltiU~I techniques to form a sheet of magnetic material, other materials can be utilized as well. For example, there is a product which is lll~l~urd~,~ul~d by Allied Corporation of Parsippany, New Jersey sold under the tradename of Metglas. This product is an amorphous alloy ribbon which has magnetic capabilities and a relatively large tensile strength. The material can be bent or otherwise formed and the amorphous or non-crystalline atomic structure of thealloys give them un;que Cl~,.,llulu~;ll.,.i~. properties. The alloy can be employed in pulse ~ r,.",.. ~ magnetic amplifiers, power ~I.. ~rullll~ and current transducers and other devices requiring a square loop high saturation material. As indicated, such materials are available from other sources as well and can be utilized to form the magnetic sheet or central member 12. The sheets 11,12 and 13 are held in place due wo 94/14174 ~1 S 0 9 ~ 3 PCT/US93/11919 Il to the ~ .".~i""c between the conductive line patterns on outer sheets 11 and 13.
The sheets can be otherwise secured together.
FIGS. 2 and 3 show planar members 11 and 13 in a top plan view, showing the parallel ~onductor line patterns.
Referring to FIG. 4, there is shown an alternate way of joining such planar sheet members. As shown in FIG. 4, planar sheet member 40 can constitute themember llorl30fFlG. 1. Essentially member 40hasconductors orconductive parallel lines, as 41 and 43, directed along the top surface or other surface and which members terminate in land areas 42 and 44 at the thin edge. These land areas arethen bridged or coupled together by means of contact members 46 and 47 which aredisposed as a top sheet or cap structure 45. In this manner the cap 45 operates to provide contact between conductors on sheets as 11 and 13 having the ~ Iri~ r~
shown in FIG. 4. This particular technique is shown in more detail in FIG. 6. FIG.
6 shows a first member 56 and a second member 49 which sandwiches the central magnetic member 57. The sheet members 49 and 56 each have a suitable pattern of parallel conductive lines on a surface. Reference numeral 48 depicts the bridge forrned by the bridging connector which operates lo connect the top ends of selected conductors. Another bridge as 48b (FIG. 6) would connect the bottom ends or terrninals. Contacts 58 and 59 are brought out from either end of the conductors as desired. Thus, in the Collri~ iull shown in 4 and 6, the members, as 45, act as a lid and have bridging contacts to enable the planar members, as 11 and 13, to be connected together by means of caps or bridging contacts without the use of via holes.
It should become apparent to those skilled in the art that other techniques for connecting the sheets together can be employed as well.
Referring to FIG. 7, there is shown one type of ~ larull.l conf~guration which can be i~ r~l using the secondary winding structures depicted in FIGS. I to 6 above. In the ~l~-larul ll.. structure of FIG .7there is shown a plurality of secondary windings, each of which is formed from a planar composite sheet, as sheet 10 of FIG. 1 and of ;lUplUpli~, length and which, surrounds a central WO 94/14174 i PCT/US93111919 --2~s09~3 12 or center primary cylinder 70. The separate secondary sheets are positioned about the primary cylinder 70 in concentric circles. Edch of the dark lines as 71, 72 and 73 represent the magnetic sheets or the planar sheets as 12, while the dashed linesrepresent the outer current sheets such as sheets 11 and 13. It is of course understood that in order to avoid electrical shorts, the respective sheets can be insulated by covering the exposed surfaces with paper or other insulators. In a similar manner the sheets can be arranged, as shown in ~IG. 7, and separated by placing a suitable shellac or other insulating material over the conductive line pattern.
Thus in the ~Idll~rOIIll-l ~illdll~ of FIG. 7 the secondary wiDdin~s are plallar sheets as those shown in FIGS. I to 6 each arran~ed in concentric circles about a primary cylinder 70. i~ach separate secondary windings sheet has two terrninals as 77 and 78 which are available via suitable leads or wires. The primary cylinder 70 is comprised of a flexible sheet such as sheet 70 shown in FIG. 9. The insulator sheet 70 of FIG. 9 is fabricated from a suitable paper and has deposited on the surface a plurality of parallel conductive lines as 125, 126, 127 and 129. The conductive lines are shown as vertically oriented but can be at slight an~les and are parallel to each other. The conductor lines teri-ninate in top and bottom land areas, as land areas 121 and 123 for conductor 125, and top land area 122 and bonom land area 124 for conductor 126 and so on. Fach conductor of the plurality has such land areas. The llexible primary sheet is bent or flexed into a circular l,V~jr~ a~iu~ and placed in the center of a secondary winding di~dll~ tO forin one portion of the primary winding. As shown in FIG. 7, the conductors 124 and 125, are arranged onthe inside of the concentric cylindrical primary structure 70. The conductive lines can also be arranged on the outside as well.
A second component of the primary winding consists in an outer concentric circular planar member 79 which again is fabricated from an insulatorsheet and has deposited ~n a surface thereof larger or wider conductive areas as 100 and 101. The number of conductive lines or areas on the outer primary cylindrical structure is the same as the number of conductive lines on the inner cylindrical ~ wo 94114174 2 ~ ~ O 9 ~ 3 PCT/US93111919 structu}e 70. As shown in FIG. 10, Ihe outer primary member 79 has parallel conductive lines 100, 101 and 102 each haYing land areas as 130 and 131 associated with conductor 102, land areas 132 and 133 associated with conductor 101 and so on.
As will be explained, the outer primary cylindrical structure 79 is connected to the inner primary cylindrical structure 70 by means of suitable conductors which may be located on cap members. The conductive line patterns arecormected togelher by means of conductive paths to form a continuous coiled primary winding which overlays the secondary winding. Conductors are directed from a inner primary conductive line as 127 on member 70 to an outer primary conductive line as conductor 101 on the outer ring 79. This is shown srhPm~irsllly in FIG. 7 by referring to conductor 140.
Referring to FIG. 11 the inner primary cylinder 70 and the outer primary cylinder 79 are shown with a secondary . .lllrlylllAlinl~ shown in dashed lines positioned LU~ lly between the primary cylinders. The arrows in the figure show the direction of nux flow through the secondary. Current flOws in the primary conductors, as for example in the primary center cylinder 70, into the paper as shown by the cross at the center. Current nOws in the outer primary conductor, as conductors 100,102 and 101, out from the paper. Hence primary current nOws into tne conductors of the central conductor 70 in a direction in the paper and out from the paper in conductors as 100, 101, 102. The conductors are arranged as follows:
Conductor 102 with top terminal 130 is connected to an inner conductor of cylinder 70 at the top terminal of the inner conductor. The bottom terminal of the inner conductor is then corlnected to a suitable bottom terminal for example of conductor 100 where the top terminal of conductor 100, as terminal 133, is connected to the top terminal of the next conductor in the line with the bottom terminal of the next - conductor connected to the bottom terminal of conductor 101 and so on. This, as one will unfipr~rl~n~i~ creates a coil pattern where the wires or c~nnPrtnrc, as 140 and 141 for example, are directed about the secondary ~ .r~..".~ as for example secondary windings 71, 72, 73 of FIG. 7. In this manner, a suitable electric field is induced to Wo 94/14174 21~ 0 9 ~ ~ PCT/US93111919 enable current flow in the primary winding to cause in current flow in the secondary windings. It is of course understood that ~ JIU~II' ' terminals such as terminal 75 associated with the iMer cylinder 70 and terminal 86 associated with the outer cylinder 79 provide the input terminals for the primary winding.
S Referring to FIG. 12 there is sflown a cap which may be fabricated from a suitable insulative material such as a ceramic, paper, cardboard or other material.
Formed ûn the bottom side of the cap, are a series of conductive land areas which are positioned near the outer peripheral of the cap, as conductors 152 and 155. Eachouter land area is coMected to an iMer land or terminal area. Thus. iMer conductive area 153 is coMected to outer conductive area 151 by means of the conductive line 152. Each outer conductive area is coMected to an iMer conductive area by a radial conductive lines as 152,156,158 and so on. The cap 150 constitutes a COMection cap or a coMectOr which coMects the outer or top terminals of primary cylinder 79 to the outer or top terminals of primary cylinder 70. In a similar manner, a bottom cap, which is configured or cap 150, constitutes another conductive pattern which operates to connect alternate bonom conductors of the iMer and ou~er primary cylinders to form an alternating or coiled pattern. The cap members are shown inFIG. 13 where a top cap 150T, and a bottom cap 150B are shown positioned with respect to the iMer and outer primary cylinders 70 and 79. The caps, as indicated, coMect the top land areas of the outer primary cylinder 79 to the ~ ylut~ , landareas of the iMer primary cylinder 70. Reference numerals 160 and 161, indicate the positions of the secondary winding sheets as shown in Fig. 7 or Fig. 8.
In FIG. 8, there is shown a spiral confi~lr~ion where one elongated member, as member 10 of FIG. 1, is arranged in a spiral coiled panern to form a secondary which is directed around a primary cylindrical member 80 associated with a primary outer cylinder 88. The primary has input terminals 83 and 84. The primary winding is structured exactly as the above-described primary consisting of primary cylinders 70 and 79 and is i~ u~ ,L~d in the same maMer, including caps as shown in FIG. 12 and FIG. 13, for example or by wires.

~ WO 94114174 215 0 9 ~ 3 PCT/US93/11919 Referring to FIG. 14 the}e is shown an en~irely different transformer configuration which essen~ially is ;.,.I,l..".. ~ from the flexible conductive planar sheets as described. above. As seen in the top view of FIG. 14, there is shown aprimary cylinder 160 and a primary cylinder 161. Each of the cylinders as 160 and 161 has the ,."lr~".,.,;,,l, shown in FIG. 9 and essentially each corlsists of a planar flexible sheet, as sheet 70 of FIG. 9, having a plurality of parallel conductive lines, as conductors 125, 126 and 127. Each of the primary cylinders are surrounded by a suitable secondary structure. such as the secondary structure shown in FIG. 7 or the secondary structure shown in FIG. 8. The conductive lines of each cylinder, are connected together by means of wires or by means of top and bottom caps to form a coil or a primary winding where current flows in the directions of the arrows shown.
The flux flow induces secondary currents to flow in the secondary structures 162 and 163. The primary winding has input terminals 170 and 171. Also shown in dashed lines is a third secondary ~ullri~ul~llioll 165 which essentially is the secondary configuration, as shown in FIGS. 7 and 8.
FIG. 15 shows the primary winding 180 with output terminals 171 and 170 in a schematic form which primary winding is now surrounded by secondary windings as 181, 182, 183 and 184. Shown in FIG. 15 are four secondary windings each of which may have a ..:...r,.... ~ ll shown in FIG. 7 or the ~ ri~ iOI~ shown in FIG. 8. It is seen that current flowing in the primary winding, which consists of four cylinders, connected together as described, induces current in the secondary windings as shown in FIG. 15.
Referring to FIG. 16, there is shown a circuit configuration of the transformer AIIAI.~,. rl-- '-1 shown in FIG. 7. As seen, the Ll~ ru,-ll~l consists of a prirnary winding having input terminals 75 and 86. The primary winding 90 is i...l,l-.,....: ~I by means of the central cylinder 70 and the outer cylinder 79 of FIG.
7. There are a plurality of secondary windings as windings 91, 92 and 93, each of which is formed from a separate, concentric, lamina sheet such as sheets 71, 72, 73 and so on of FIG. 7. Each of the separate secondary windings as indicated have two L: ~
WO 94114174 2 i S ~ 9 S 3 PCTIUS93/1 1919 terminals and can be illLtl~ulul~ by means ûf diodes or rectifiers, such as 101,shown connecting one terminal of secondary winding 92 to one terminal of secondary winding 91.
Referring to FIG. 17, there is shown a schematic diagram depicting a S circuit cr~nf~ rAtinn of the transformer ,~ shown in FIG. 8. As se~n, the primary winding 95 has input terminals 83 and 84 and is associated with a large secondary winding 96 having terminals 81 and 82, which winding 96 consists of the spiral winding having many turns and therefore is capable of extremely high volta~e step-up ratios.
As one can ascenain from FIGS. 7 and 8, the l,d,,aru.,,,.l shown utilize rolled flexible planar sheets, essentially are rolled up employing similar techniques used in forming capacitors. Such Lld.larul~ are extremely reliable and possess many features which are not found in ~:UII~ iOlldl lldllarUIlll.la. The transformers exhibit a higher efficiency in the range of 95% or greater and exhibit extremely good voltage regulation of about 0.97Mohms. These l~dll~rull~.~.ls have high frequency responses to 100 kHz. The ~ Ilarullll~,la have extremely good eMciency and a very optimum usage of Lldllarullll~l materials based on their CullaLIu~liull. As one will n~ r~t~nrl a secondary core is fabricated with a number of concentric and t~ ,u~ thin anmular rings, as for example shown in FIG. 7. Each of the rings is capable of ~ o~ a maximum number of current carrying conductors, such as 11 and 13 of FIG. 1. Thus the core material which is evidenced by planar member 12 of FIG. l is fully and most efficiently excited. The result is a much higher attainable voltage than can be realized with a single prior art core with one winding.
It is also indicated that the planar sheets are folded in an annular or concentric ring patterns with an input terminal, as for example 31, providing one terminal of a secondary winding and the output terminal 35 providing the second output terrninal. As indicated, these windings can be directly connected together to form a single secondary winding or can be connected by means of rectifiers. For a ~ wO 94/14174 21 S O 9 ~ 3 PCT/US93/11919 given primary excitation with a single prior art secondary core and winding, theop~imum ratio of the two radii for the higher secondary voltage is 1.6487. At thc same ratio, the attainable secondary voltage with a secondary core comprised of a given number of concentric planar sheets, as for example shown in FIG. 7, is 1.718 times higher. The available secondary voltage from the improved devices is three or four times higher than that obtained with conventional Lldl,~ru..~
Improved operation is also due to the fact that the current excitation is provided via the wireless tapes or planar members which have evaporated conductors on the surface and which closely couple to the central magnetic sheet or magnetic member resulting in practically no local leakage for the Lldll~ru.l.l~,.. Thus the lldll~rullll~., while being extremely efhcient, isextremely small ~ull~;d..illg the voltage levels operated on.

Claims (21)

Claims

1. A transformer secondary winding comprising:
a flexible laminated member, comprising a first planar sheet member having a first plurality of parallel conductive lines on a surface thereof, a second planar sheet member having a second plurality of parallel conductive lines of a surface thereof, a central planar sheet member fabricated from a magnetizable material interposed between said first and second planar members;
and connecting means for connecting ends of said first and second parallel lines to one another to form a coiled pattern directed about said central member to enable any current flowing in said coiled pattern to magnetizesaid central planar sheet according to said current flow, said connecting means comprising cap structures adapted to couple to respective sides of said flexiblelaminated member, whereby said ends of said first and second parallel lines are connected to one another, said first, second and central planar sheet and said connecting means forming a composite flexible member, said composite flexible member being manipulable into various transformer configurations.

2. The transformer secondary winding according to Claim 1 wherein said first sheet is fabricated from a flexible insulative material having said first plurality of conductive lines on a surface thereof.

3. The transformer secondary winding according to Claim 1 wherein said second sheet is fabricated from a flexible insulative material having said second plurality of conductive lines on a surface thereof.

4. The transformer secondary winding according to Claim 1 wherein said first and second sheets are fabricated from paper.

5. The transformer secondary winding according to Claim 1 wherein said central planar sheet is fabricated from a soft iron.

6. The transformer secondary winding according to Claim 1 wherein said first plurality of parallel lines are each at an angle with respect to the vertical and with said second plurality of lines at a different angle to form a zig-zag coiled pattern.

7. The transformer secondary winding according to Claim 1 wherein said laminated member is arranged in a circle to form a cylindrical transformer secondary winding.

8. A transformer apparatus, comprising:
an inner primary structure of a first flexible sheet having a plurality of parallel primary conductive lines disposed on a surface, said sheetflexed to form a first primary cylinder, at least one secondary winding of a flexible laminated member comprising first and second insulator sheets separated by a third magnetizable sheet, with said first sheet having a first plurality of conductivelines on a surface thereof and with said second sheet having a second plurality of conductive lines on a surface thereof, with the ends of said first lines connected to ends of said second lines to form an alternating line pattern between said first and second sheets to surround said magnetizable sheet with a coiled conductive pattern, said flexible laminated member arranged in a circular configuration concentrically about said first primary cylinder;
an outer primary structure of a second flexible sheet having a second plurality of parallel primary conductive lines disposed on a surface, said second flexible sheet concentrically surrounding said secondary winding; and means for connecting selected ends of said first primary conductive lines to selected ends of said second primary conductive lines to form a primary winding disposed about said secondary winding to enable current flowing in said primary winding to induce current flow in said secondary winding.

9. The apparatus according to Claim 8 further including another secondary winding of flexible laminated member arranged as said least one laminated member and concentrically surrounding said at least one secondary winding to form another secondary winding with said another winding positioned between said at least one secondary winding and said outer primary winding.

10. The apparatus according to Claim 9 including rectifier means coupling said one secondary winding to said another secondary winding.

11. The apparatus according to Claim 9 wherein said flexible insulator sheets are fabricated from paper.

12. The apparatus according to Claim 9 wherein said magnetizable sheets are fabricated from a soft iron.

13. The apparatus according to Claim 9 wherein each of said lines on said first sheet are at a given angle with respect to the vertical, with each of said lines on said second sheet at another angle with respect to the vertical to enable said lines to form a zig-zag coiled pattern when the ends are connected.

14. The apparatus according to Claim 13 wherein said sheets are each about 1 mil thick.

15. The apparatus according to Claim 8 wherein said means for connecting selected ends of said first primary conductive lines to selective ends of said second primary conductive lines comprises first and second cap member ends having a radial line pattern disposed on a surface and with said top memberoperative to connect the top terminal of a conductive line on said inner primarywinding to the top terminal of a conductive line on said outer primary structure, and with said bottom member operative to connect selected bottom terminals of conductive lines on said inner and outer primary structures to provide said primary coil winding due to said connections.

16. The transformer according to Claim 8 wherein said at least one secondary winding is coiled to assume a spiral configuration.

17. A transformer apparatus comprising:
first and second flexible primary sheets, each having a plurality of parallel conductive lines disposed on a surface, and each flexed toform a cylinder, with a first cylinder spaced apart from a second cylinder, eachof said lines having a top terminal and a bottom terminal;
means for interconnecting top and bottom terminals of said conductive lines of said first cylinder with top terminals of conductive lines of said second cylinder to form a coiled primary winding between said first and second cylinders;
at least one first secondary winding of a flexible laminated member comprising first and second insulator sheets separated by a magnetizable sheet, with said first sheet having a first plurality of conductive lines on a surface thereof and with said second sheet having a second plurality of conductive lineson a surface thereof, with the ends of said first lines connected to ends of said second lines to form an alternating line pattern between said first and second sheets to surround said another magnetizable sheet with a coiled conductive pattern, with said flexible laminate member arranged in a circular configurationwhich concentrically surrounds said first primary cylinder;
at least one second secondary winding of a flexible laminated member comprising third and fourth insulator sheets separated by another magnetizable sheet, with said third sheet having a third plurality of conductive lines on a surface thereof and with said fourth sheet having a fourthplurality of conductive lines on a surface thereof, with the ends of said third lines connected to ends of said fourth lines to form an alternating line pattern between said third and fourth sheets to surround said another magnetizable sheet with a coiled conductive pattern, with said flexible laminate member arranged in a circular configuration which concentrically surrounds said second primary cylinder whereby current flowing in said primary winding induces current flow in said first and second secondary windings.

18. The transformer apparatus according to Claim 17 wherein said flexible primary sheets are insulative sheets.

19. The transformer apparatus according to Claim 17 wherein said magnetizable sheets are soft ion sheets.

20. The transformer according to Claim 18 wherein said flexible primary sheets are fabricated from paper.

21. The transformer apparatus of Claim 1, wherein said first and second plurality of conductive lines terminate in land areas disposed on top andbottom surfaces of said first and second planar sheets, said cap structure including contact regions adapted to coact with said land areas.