Magnetic component with bobbinless winding
View Patent ↗A transformer having a bobbinless winding assembly positioned on a base includes a primary winding having multiple radially-spiraling turns of a wire and a secondary winding including a substantially planar annular disk having a radial gap defined therein. A primary winding having first and second primary windings including multiple radially-spiraling turns of wire with free ends extending from outer turns and a method of forming the same is provided. A secondary winding having a planar annular disk with a radial gap defined therein and a method of forming the same is also provided.
1. A transformer apparatus comprising:
a base;
a bobbinless winding assembly disposed on the base, the assembly comprising:
a primary winding including an electrically conductive wire having a plurality of substantially co-planar radially-spiraling turns of the wire;
a secondary winding aligned co-axially with the primary winding, the secondary winding including a substantially planar disk having a radial gap defined therein, the primary and secondary windings having a center axis defining an interior void along the center axis;
a core positioned in the interior void, the base positioned on the exterior of winding assembly;
a toroidal current-sense transformer positioned on the base, the current-sense transformer defining a center hole therein; and
the primary winding including a free end passing through the center hole.
2. The apparatus of claim 1 , further comprising:
a first terminal pin protruding from the base;
a second terminal pin protruding from the base;
wherein each terminal pin is electrically connected to the primary winding.
3. The apparatus of claim 1 , wherein:
the primary winding further comprises first and second primary windings co-axially aligned and electrically connected in series; and
wherein the first and second primary windings are separated by a primary winding gap.
4. The apparatus of claim 3 , wherein the annular disk of the secondary winding is positioned in the primary winding gap aligned co-axially with the first and second primary windings.