| US 7,489,226 B1 | ||
| Fabrication method and structure for embedded core transformers | ||
| Bruce W. Chignola, Marlborough, Mass. (US); Boris S. Jacobson, Westford, Mass. (US); Donald H. Desrosiers, Marlborough, Mass. (US); and Dennis R. Kling, Milford, Mass. (US) | ||
| Assigned to Raytheon Company, Waltham, Mass. (US) | ||
| Filed on May 09, 2008, as Appl. No. 12/151,870. | ||
| Int. Cl. H01F 27/28 (2006.01) | ||
| U.S. Cl. 336—229 | 37 Claims |
| 1. An embedded core transformer comprising:
a base enclosure having a base wall and a perimeter wall forming a cavity with an open top;
a magnetic core disposed inside the cavity comprising a volume of magnetic material formed as a closed magnetic circuit having
a plurality of magnetic circuit legs;
a plurality of conductive winding elements disposed inside the cavity, each comprising a conductive sheet metal element formed
to partially encircle one of the magnetic circuit legs, wherein each conductive sheet metal element includes three legs with
two of the three legs formed to extend above the perimeter wall through the open top;
means, sized to attach to the perimeter wall for closing the open top, for electrically interconnecting with each winding
element by connecting with the two legs that extend above the perimeter wall and further configured with first conductive
traces for forming a primary winding circuit that includes a first portion of the winding elements and second conductive traces
for forming a secondary winding circuit that includes a remaining portion of the winding elements; and,
wherein the primary winding circuit is inductively coupled with the secondary winding circuit through the magnetic core.
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