U.S. patent application number 13/646546 was filed with the patent office on 2014-05-15 for slat-constructed autonomic transformers.
The applicant listed for this patent is Ross W. Bird, William M. Bradley, Gareth J. Knowles. Invention is credited to Ross W. Bird, William M. Bradley, Gareth J. Knowles.
Application Number | 20140132118 13/646546 |
Document ID | / |
Family ID | 48044425 |
Filed Date | 2014-05-15 |
United States Patent
Application |
20140132118 |
Kind Code |
A9 |
Bird; Ross W. ; et
al. |
May 15, 2014 |
SLAT-CONSTRUCTED AUTONOMIC TRANSFORMERS
Abstract
Multilayered piezoelectric transformers, transformer elements
and methods of constructing piezoelectric transformers are
disclosed.
Inventors: |
Bird; Ross W.; (Canton,
PA) ; Bradley; William M.; (Lewisburg, PA) ;
Knowles; Gareth J.; (Williamsport, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bird; Ross W.
Bradley; William M.
Knowles; Gareth J. |
Canton
Lewisburg
Williamsport |
PA
PA
PA |
US
US
US |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20130278115 A1 |
October 24, 2013 |
|
|
Family ID: |
48044425 |
Appl. No.: |
13/646546 |
Filed: |
October 5, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61543708 |
Oct 5, 2011 |
|
|
|
Current U.S.
Class: |
310/359 ;
29/25.35; 310/357; 310/366 |
Current CPC
Class: |
H01L 41/107 20130101;
Y10T 29/42 20150115; H01L 41/27 20130101; H01L 41/0833 20130101;
H01L 41/0471 20130101 |
Class at
Publication: |
310/359 ;
310/366; 310/357; 29/25.35 |
International
Class: |
H01L 41/107 20060101
H01L041/107; H01L 41/27 20060101 H01L041/27 |
Goverment Interests
I. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] This invention was made with government support under
Contract No. FA9453-11-C-0076 awarded by the United States Air
Force. The government has certain rights in the invention.
Claims
1. A modular slat comprising: a dielectric member of substantially
uniform planar thickness, said dielectric member having first and
second opposing faces and a sidewall; a first electrode assembly
disposed on the first face, said first electrode assembly
including: an outer electrode disposed along an outer boundary of
the first face and having a discontinuous region, the outer
electrode including first and second cutouts, the outer electrode
further including an outer electrode tab extending along the
sidewall from the first face towards the second face; an inner
electrode disposed substantially concentric with the outer
electrode, the inner electrode including a central region and a leg
extending from the central region to an edge of the first face and
an inner electrode tab extending along the sidewall from the leg
towards the second face; an insulation region disposed between the
first and second electrodes; a second electrode assembly disposed
on the second face where the second electrode assembly is
asymmetrically arranged relative to the first electrode assembly,
the second electrode assembly including: an outer electrode
disposed along an outer boundary of the second face and having a
discontinuous region, the outer electrode including first and
second cutouts that are aligned with the inner and outer electrode
tabs of said first electrode assembly, the outer electrode further
including a tab extending along the sidewall from the second face
towards the first face and aligned with one of the first and second
cutouts; an inner electrode disposed substantially concentric with
the outer electrode, the inner electrode including a central region
and a leg extending from the central region to an edge of the
second face and a tab extending along the sidewall from the leg
towards the first face and aligned with the other of the first and
second cutouts; and an insulation region disposed between the first
and second electrodes of the second electrode assembly.
2. The modular slat member of claim 1 wherein said dielectric
member is uniformly axially polled in the positive z direction.
3. The modular slat of claim 1 wherein said dielectric member is
uniformly axially polled in the negative z direction.
4. The modular slat of claim 1 wherein said dielectric member is
non-uniformly axially polled and includes regions axially polled in
the positive z direction and regions axially polled in the negative
z direction.
5. A modular slat comprising: a dielectric member of substantially
uniform planar thickness, said dielectric member having first and
second opposing faces and a sidewall; a first electrode assembly
disposed on the first, said first electrode assembly including: an
outer electrode disposed along an outer boundary of the first face
and having a discontinuous region, the outer electrode including
first and second cutouts, the outer electrode further including an
outer electrode tab extending along the sidewall from the first
face towards the second face; an inner electrode disposed
substantially concentric with the outer electrode, the inner
electrode including a central region and a leg extending from the
central region to an edge of the first face and an inner electrode
tab extending along the sidewall from the leg towards the second
face; an insulation region disposed between the outer and inner
electrodes of the first electrode assembly; a central electrode
disposed in the insulation region substantially concentric with the
inner and outer electrodes, the central electrode including at
least a first leg extending from the central region to an edge of
the first face and a central electrode tab extending along the
sidewall from the first leg towards the second face; a second
electrode assembly disposed on the second face where the second
electrode assembly is asymmetrically arranged relative to the first
electrode assembly, the second electrode assembly including: an
outer electrode disposed along an outer boundary of the second face
and having a discontinuous region, the outer electrode including
first and second cutouts that are aligned with the inner, central
and outer electrode tabs of said first electrode assembly, the
outer electrode further including a tab extending along the
sidewall from the second face towards the first face and aligned
with one of the first and second cutouts; an inner electrode
disposed substantially concentric with the outer electrode, the
inner electrode including a central region and a leg extending from
the central region to an edge of the second face and a tab
extending along the sidewall from the leg towards the first face
and aligned with the other of the first and second cutouts; and an
insulation region disposed between the inner and outer electrodes
of the second electrode assembly; and a central electrode disposed
in the insulation region substantially concentric with the inner
and outer electrodes, the central electrode including at least a
first leg extending to an edge of the second face and a central
electrode tab extending along the sidewall from the first leg
towards the first face, the tab being in alignment with at least
one of the cutouts of the outer electrode of the first face.
6. The modular slat member of claim 5 wherein said dielectric
member is uniformly axially polled in the positive z direction.
7. The modular slat of claim 5 wherein said dielectric member is
uniformly axially polled in the negative z direction.
8. The modular slat of claim 5 wherein said dielectric member is
non-uniformly axially polled and includes regions axially polled in
the positive z direction and regions axially polled in the negative
z direction.
9. The modular slat of claim 5 wherein the central electrode tab
and the inner electrode tab of the first electrode assembly are
aligned with the first cutout of the outer electrode of said second
electrode assembly.
10. The modular slat of claim 9 wherein the central electrode tab
and the inner electrode tab of the second electrode assembly are
aligned with the first cutout of the outer electrode of said first
electrode assembly.
11. A multilayer ceramic core transformer element comprising: a
ceramic member of substantially uniform thickness, said ceramic
member having first and second opposing faces and a sidewall; a
first electrode assembly disposed on the first face, the electrode
assembly including at least two electrically isolated electrodes
separated by a non-conducting region, said first electrode assembly
including a plurality of tabs extending along the sidewall of said
ceramic member towards said second face; a plurality of
non-conductive tab receiving regions disposed on the first face of
said ceramic member, said tab receiving regions being free from
electrodes; a second electrode assembly disposed on the second face
asymmetric with respect to said first electrode assembly, the
second electrode assembly including at least two electrically
isolated electrodes separated by a non-conducting region, said
second electrode assembly including a plurality of tabs extending
along the sidewall of said ceramic member towards said first face;
a plurality of non-conductive tab receiving regions disposed on the
second face of said ceramic member, said tab receiving regions
being free from electrodes, the non-conductive tab receiving
regions of the second face being axially aligned with the plurality
of tabs of said first electrode assembly and the non-conductive tab
regions of the first face being axially aligned with the plurality
of tabs of said second electrode assembly.
12. A multilayer ceramic core transformer comprising: a first
ceramic member of substantially uniform thickness, said ceramic
member having first and second opposing faces and a sidewall, said
first ceramic member including: a first electrode assembly disposed
on the first face, the electrode assembly including at least two
electrically isolated electrodes separated by a non-conducting
region, said first electrode assembly including a plurality of tabs
extending along the sidewall of said ceramic member towards said
second face; a plurality of non-conductive tab receiving regions
disposed on the first face of said ceramic member, said tab
receiving regions being free from electrodes; a second electrode
assembly disposed on the second face asymmetric with respect to
said first electrode assembly, the second electrode assembly
including at least two electrically isolated electrodes separated
by a non-conducting region, said second electrode assembly
including a plurality of tabs extending along the sidewall of said
ceramic member towards said first face; a plurality of
non-conductive tab receiving regions disposed on the second face of
said ceramic member, said tab receiving regions being free from
electrodes, the non-conductive tab receiving regions of the second
face being axially aligned with the plurality of tabs of said first
electrode assembly and the non-conductive tab regions of the first
face being axially aligned with the plurality of tabs of said
second electrode assembly; and a second ceramic member of
substantially uniform thickness, said ceramic member having first
and second opposing faces and a sidewall, said first ceramic member
including: a first electrode assembly disposed on the first face,
the electrode assembly including at least two electrically isolated
electrodes separated by a non-conducting region, said first
electrode assembly including a plurality of tabs extending along
the sidewall of said ceramic member towards said second face; a
plurality of non-conductive tab receiving regions disposed on the
first face of said ceramic member, said tab receiving regions being
free from electrodes; a second electrode assembly disposed on the
second face asymmetric with respect to said first electrode
assembly, the second electrode assembly including at least two
electrically isolated electrodes separated by a non-conducting
region, said second electrode assembly including a plurality of
tabs extending along the sidewall of said ceramic member towards
said first face; a plurality of non-conductive tab receiving
regions disposed on the second face of said ceramic member, said
tab receiving regions being free from electrodes, the
non-conductive tab receiving regions of the second face being
axially aligned with the plurality of tabs of said first electrode
assembly and the non-conductive tab regions of the first face being
axially aligned with the plurality of tabs of said second electrode
assembly; said first ceramic member being stacked with said second
ceramic member such that the second face of said first ceramic
member is substantially parallel with the first face of said second
ceramic member and at least one of the plurality of tabs of the
second electrode assembly of said first ceramic element is axially
aligned with at least one of the plurality of tabs of the first
electrode assembly of said second ceramic element.
13. The multilayer ceramic core transformer of claim 12 further
comprising an electrically conductive adhesive connecting one the
at least two electrodes of the second electrode assembly of the
first ceramic element to respective electrodes of the first
electrode assembly of the second ceramic element.
14. The multilayer ceramic core voltage transformer of claim 13
wherein at least one tab of the first electrode assembly of the
first ceramic member is electrically connected to at least one tab
of the second electrode assembly of the second ceramic member.
15. The multilayer ceramic core voltage transformer of claim 14
wherein the first ceramic element is uniformly axially polled in
the positive z direction.
16. The multilayer ceramic core voltage transformer of claim 15
wherein the second ceramic element is uniformly polled in the
negative z direction.
17. The multilayer ceramic core voltage transformer of claim 15
wherein the second ceramic element includes regions that are
axially polled in the positive z direction and regions that are
axially polled in the negative z direction.
18. The multilayer ceramic core voltage transformer of claim 14
wherein the first ceramic element includes regions that are axially
polled in the positive z direction and regions that are axially
polled in the negative z direction.
19. The multilayer ceramic core voltage transformer of claim 18
wherein the second ceramic element is uniformly axially polled in
the negative z direction.
20. A method of constructing a multilayer ceramic core transformer
comprising: selecting first and second ceramic elements, each
ceramic element comprising: a ceramic member of substantially
uniform thickness, said ceramic member having first and second
opposing faces and a sidewall; a first electrode assembly disposed
on the first face, the electrode assembly including at least two
electrically isolated electrodes separated by a non-conducting
region, said first electrode assembly including a plurality of tabs
extending along the sidewall of said ceramic member towards said
second face; a plurality of non-conductive tab receiving regions
disposed on the first face of said ceramic member, said tab
receiving regions being free from electrodes; a second electrode
assembly disposed on the second face asymmetric with respect to
said first electrode assembly, the second electrode assembly
including at least two electrically isolated electrodes separated
by a non-conducting region, said second electrode assembly
including a plurality of tabs extending along the sidewall of said
ceramic member towards said first face; a plurality of
non-conductive tab receiving regions disposed on the second face of
said ceramic member, said tab receiving regions being free from
electrodes, the non-conductive tab receiving regions of the second
face being axially aligned with the plurality of tabs of said first
electrode assembly and the non-conductive tab regions of the first
face being axially aligned with the plurality of tabs of said
second electrode assembly; arranging the first and second ceramic
elements in a stacked configuration such that the electrode
assembly of the second face of the first ceramic element is
coincident with the electrode assembly of first face of the second
ceramic element; bonding the electrodes of the second face of the
first ceramic element to opposing electrodes of the first face of
the second ceramic element; electrically connecting at least one of
the tabs of the first electrode assembly of the first ceramic
element to at least one of the tabs of the second electrode
assembly of said second ceramic element.
Description
[0001] This application claims the benefit of U.S. provisional
Application Ser. No. 61/543,698, filed Oct. 5, 2011, which is
hereby incorporated by reference in its entirety.
II. FIELD OF THE INVENTION
[0003] The present application relates to autonomic transformers
and methods for constructing the same.
III. BACKGROUND TO THE INVENTION
[0004] Single layer and multilayer Ceramic transformers offer a
number of advantages over standard electromagnetic based
transformers including ease of miniaturization and high galvanic
isolation. However, impediments exist that have made single layer
and multilayer ceramic transformers unattractive in applications
that generally employ standard isolated magnetic DC/AC voltage
level shift devices.
[0005] Ceramic transformers can be categorized into three types:
Rosen type, thickness vibration type, and planar vibration-type,
displayed in prior art FIG. 1a, FIG. 1b, and FIG. 2a. Among the
three types, Rosen type transformers are most common as they
traditionally provide the highest voltage gain and power density
for DC-DC or AC-DC converter applications. However, several major
challenges have prevented wider acceptance of ceramic
transformers.
[0006] Although ceramic transformers are inherently very highly
power dense devices, power handling and power throughput are
distinct issues. Existing ceramic transformers are of high power
density, but the voltage range in which they operate optimally is
too high for typical modern electronics. The issue is not one of
power density (ceramic transformers are typically capable of 40-50
W/cm.sup.3). The issue is that the power throughput supply voltage
requirements necessary to achieve appropriate power throughput are
higher than normally supplied by conventional applications and that
such high supply voltage is likely to rapidly cause internal damage
to the ceramic transformer.
[0007] It is believed that one of the underlying reasons for this
lack of power throughput performance is a lack of ability to design
or control by construction both the supply side impedance and the
load side impedance of the existing ceramic transformers. To obtain
improved power throughput requires both the supply side impedance
and the load side impedance must be simultaneously addressed. Prior
art ceramic transformer designs, including multilayer ceramic
transformer designs, do not exhibit the ability to adjust both the
input and the output impedance characteristics to control the power
throughput. Accordingly, there is a need for a ceramic transformer
design that can simultaneously enable impedance selectivity at both
input and output through construction selection as to both provide
a more agile application capability, a superior power throughput
capability and a lower cost of manufacture. The invention provides
for such capability.
[0008] Another challenge to wide implementation of existing ceramic
transformers is that it is difficult to design ceramic transformers
for efficient step-down voltage gain at higher power. For example,
there are fundamental problems at present in attempting to employ
known ceramic transformer devices for low impedance (high
current/low voltage) applications for small electronics devices
such as cell phones and iPod chargers and similar such converter or
isolator applications. In many existing ceramic transformers, the
voltage gain automatically increases as the output load decreases.
This leads to a difficulty in that increasing power capability for
such ceramic transformers directly leads to impedance mismatch at
low impedance output electrical loading conditions. What is needed
is a method to provide moderate to large step down ratios in a
manner that maximizes mechanical coupling efficiencies and enables
significant power throughput.
[0009] Still another challenge of the prior art is that known
ceramic transformers tend to be "gain specific". Prior art ceramic
transformers are generally either step-up type or, much more
rarely, a step-down type of a small step-down ratio. A common
approach to achieving step-down capability is simply to reverse the
input and output connections. However, this approach leads to
further limiting power throughput and a reduction in efficiency.
What is needed is a method to provide both moderate and large power
levels and step-down ratios in a single modular design that
maximizes electrical power conversion efficiency and enables
significant power throughput.
[0010] More recent developments in piezoelectric transformer
technology, as exemplified in (a) Vo Viet et al, "Investigation of
the Optimum Design for a 10 W Step-down 3-layer Piezoelectric
Transformer," Journal of the Korean Physical Society, 58, No. 3,
March 2011 and (b) Kim, Insung et al, "Ring-dot-shaped Multilayer
Piezoelectric Step-down Transformers Using PZT-based Ceramics",
Journal of the Korean Physical Society, Vol. 57, No. 4 (2010), have
sought to use the advantage of unipoled transformer construction in
multilayer designs, as disclosed in U.S. Pat. No. 5,278,471, as to
enable step-down transform capability. FIG. 1a and FIG. 1b
illustrate an exemplary representation of such a multilayer
unipoled piezoelectric transformer. The device of FIG. 1a and FIG.
1b has certain design and performance limitations. Because the
innermost electrode region 101, at the center of the ring or
annulus areas 103, are electrically inaccessible all the individual
`central dot` layers which comprise region 107 must be uniformly
poled in a common direction. This causes the central ring to act as
a single piece of ceramic and though it is physically a multilayer
construction it is electrically a single poled layer. Each
additional layer, or increased thickness, reduces the capacitance
of the center dot region thus increasing the impedance of the
respective port of the transformer. This increase in output
impedance then reduces the effectiveness of the device as a
step-down transformer. Additionally, this restriction obviates the
ability to selectively control the effective impedance as seen by
the input side AC drive voltage which prevents enabling higher
power throughput in many situations such as one-to-one or step-down
transform ratio applications.
[0011] The configuration of FIG. 1a can add additional layers of
either alternating or common poling direction interlace. However,
irrespective of the number of layers and poling orientation
selections, the prior art of FIG. 1a and FIG. 1b is further limited
to operate either in Series-in/Parallel-out mode,
Parallel-in/Series-Out mode, or Series-in/Series-out mode of
electrical configuration. In particular, prior art exemplified by
FIG. 1a and FIG. 1b precludes any feasible realization of a
Parallel-in/Parallel-out, which creates the ability to create a low
output and input impedance, operation, but it is precisely this
configuration that is essential to larger voltage step-down
applications of piezoelectric transformer constructions that
exhibit high efficiencies and high power throughput.
[0012] The prior art as exemplified in FIG. 1a and FIG. 1b has
another undesirable set of restrictions. The electrode design
arrangement is not conducive to either low cost production or
scalability in terms of voltage transformation or power level.
Increasing or decreasing the number of layers in the design becomes
a complicated modeling and redesign challenge. Additionally, no
modular approach to layer fabrication or assembly can be
applied.
[0013] FIG. 2a presents a planar mode single layer piezoelectric
transformer in a toroidal form factor. Turning to FIG. 2b, the
concept of a Parallel-in/Parallel-out mode operation is achieved
utilizing a pair of devices of FIG. 2a, but is done so at the cost
of physical separation the piezoelectric elements. Unavoidable
variation in resonant frequency, no matter the tolerance of
fabrication, will cause such a solution to perform at reduced
efficiencies. The variation in resonant frequency between device
201 and device 203, in FIG. 2b, causes the need for a sacrifice to
be made when driving the devices from a single source 205. Since
the devices 201 and 203 will have two distinct resonant frequencies
they can't be driven in parallel efficiently from a single
frequency source 205. This problem becomes most pronounced when
attempting to parallel multiple elements, as the mean variation in
resonant frequency increases, the overall performance of the
combined of devices will decrease. The present invention aims to
eliminate this issue of variation in frequency by physically
coupling the layers as a single mechanical structure. When fully
mechanically coupled, the stack itself has a single resonant
frequency, thus individual layers in the stack operate at this
single resonant frequency, eliminating any reduction in performance
from phase cancelation and off-resonant operation.
IV. SUMMARY OF THE INVENTION
[0014] In some embodiments the invention is directed to novel
multilayer transformers and transformer elements. In other
embodiments the invention is directed to novel methods for
assembling multilayer transformers.
[0015] More particularly, in one embodiment, the invention is
directed to a modular slat usable for building a multilayer
transformer. The slat includes a dielectric structural element of
substantially uniform planar thickness, which has first and second
opposing faces and a sidewall. A first electrode assembly is
overlayed on the first face. The first electrode assembly has an
outer electrode disposed along an outer boundary of the first face
and a discontinuous region. The outer electrode has first and
second cutouts and the outer electrode also has an outer electrode
tab extending along the sidewall from the first face towards the
second face.
[0016] The first electrode assembly further includes an inner
electrode disposed substantially concentric with the outer
electrode. The inner electrode includes a central region and a leg
extending from the central region to an edge of the first face. An
inner electrode tab extends along the sidewall from the leg towards
the second face. An insulation region is positioned between the
first and second electrodes.
[0017] A second electrode assembly is overlayed on the second face
of the slat and asymmetrically arranged relative to the first
electrode assembly. The second electrode assembly has an outer
electrode disposed along an outer boundary of the second face and a
discontinuous region or discontinuity. The outer electrode includes
first and second cutouts that are aligned with the inner and outer
electrode tabs of the first electrode assembly. The outer electrode
further includes a tab extending along the sidewall from the second
face towards the first face where the tab is aligned with one of
the first and second cutouts.
[0018] The second electrode assembly also has an inner electrode
disposed substantially concentric with the outer electrode. The
inner electrode has a central region and a leg extending from the
central region to an edge of the second face and a tab extending
along the sidewall from the leg towards the first face and aligned
with the other of the first and second cutouts.
[0019] The second electrode assembly further includes an insulation
region disposed between the first and second electrodes.
[0020] The invention further encompasses another embodiment of a
modular slat usable for building multilayer transformers. In this
embodiment, the modular slat includes a dielectric structural
member of substantially uniform planar thickness, which has first
and second opposing faces and a sidewall. A first electrode
assembly is overlayed on the first face. The first electrode
assembly has an outer electrode disposed along an outer boundary of
the first face and a discontinuous region. The outer electrode has
first and second cutouts and the outer electrode also has an outer
electrode tab extending along the sidewall from the first face
towards the second face.
[0021] The first electrode assembly further includes an inner
electrode disposed substantially concentric with the outer
electrode. The inner electrode includes a central region and a leg
extending from the central region to an edge of the first face. An
inner electrode tab extends along the sidewall from the leg towards
the second face. An insulation region is positioned between the
first and second electrodes.
[0022] A central electrode is disposed in the insulation region
substantially concentric with the inner and outer electrodes. The
central electrode includes at least a first leg extending to an
edge of the first face and a central electrode tab extending along
the sidewall from the first leg towards the second face.
[0023] A second electrode assembly is overlayed on the second face
of the slat and asymmetrically arranged relative to the first
electrode assembly. The second electrode assembly has an outer
electrode disposed along an outer boundary of the second face and a
discontinuous region or discontinuity. The outer electrode includes
first and second cutouts that are aligned with the inner and outer
electrode tabs of the first electrode assembly. The outer electrode
further includes a tab extending along the sidewall from the second
face towards the first face where the tab is aligned with one of
the first and second cutouts.
[0024] The second electrode assembly also has an inner electrode
disposed substantially concentric with the outer electrode. The
inner electrode has a central region and a leg extending from the
central region to an edge of the second face and a tab extending
along the sidewall from the leg towards the first face and aligned
with the other of the first and second cutouts.
[0025] The second electrode assembly further includes an insulation
region disposed between the first and second electrodes. A central
electrode is disposed in the insulation region substantially
concentric with the inner and outer electrodes, the central
electrode includes at least a first leg extending to an edge of the
second face and a central electrode tab extending along the
sidewall from the first leg towards the first face, the tab being
in alignment with at least one of the cutouts of the outer
electrode of the first face.
[0026] In accordance with another aspect of the invention, a novel
multilayer ceramic core transformer element is claimed. The ceramic
element includes a ceramic member of substantially uniform
thickness, which has first and second opposing faces and a
sidewall. A first electrode assembly is overlayed on the first face
of the ceramic element. The first electrode assembly has at least
two electrically isolated electrodes separated by a non-conducting
region and a plurality of tabs extending along the sidewall of said
ceramic member towards the second face.
[0027] A plurality of non-conductive tab receiving regions are
disposed on the first face of the ceramic member, the tab receiving
regions are free from electrodes and generally non-conductive.
[0028] A second electrode assembly is disposed on the second face
of the ceramic member and asymmetrically positioned with respect to
the first electrode assembly. The second electrode assembly has at
least two electrically isolated electrodes separated by a
non-conducting region. The second electrode assembly also has a
plurality of tabs extending along the sidewall of said ceramic
member towards the first face.
[0029] A plurality of non-conductive tab receiving regions are
disposed on the second face of said ceramic member, where the tab
receiving regions are free from electrodes and generally
non-conductive. The non-conductive tab receiving regions of the
second face are axially aligned with the plurality of tabs of the
first electrode assembly and the non-conductive tab regions of the
first face are axially aligned with the plurality of tabs of the
second electrode assembly.
[0030] In still another embodiment, the invention is directed to a
multilayer ceramic core transformer. The transformer includes a
first ceramic member of substantially uniform thickness, which has
first and second opposing faces and a sidewall. The ceramic member
has a first electrode assembly disposed on its first face where the
electrode assembly includes at least two electrically isolated
electrodes separated by a non-conducting region. The first
electrode assembly also has a plurality of tabs that extend along
the sidewall of the ceramic member towards its second face.
[0031] A plurality of non-conductive tab receiving regions disposed
on the first face of the ceramic member which are free from
electrodes and generally non-conductive.
[0032] A second electrode assembly is disposed on the second face
and positioned asymmetrically with respect to the first electrode
assembly. The second electrode assembly has at least two
electrically isolated electrodes separated by a non-conducting
region and a plurality of tabs extending along the sidewall of the
ceramic member towards its first face.
[0033] A plurality of non-conductive tab receiving regions are
disposed on the second face of the first ceramic member and are
axially aligned with the plurality of tabs of the first electrode
assembly. The non-conductive tab regions of the first face are
axially aligned with the plurality of tabs of the second electrode
assembly.
[0034] A second ceramic member of substantially uniform thickness
with first and second opposing faces and a sidewall is stacked with
the first ceramic member. The second ceramic member has a first
electrode assembly disposed on its first face, where the first
electrode assembly has at least two electrically isolated
electrodes separated by a non-conducting region and a plurality of
tabs extending along the sidewall of the second ceramic member
towards its second face.
[0035] A plurality of non-conductive tab receiving regions are
disposed on the first face of the second ceramic member, where the
tab receiving regions being free from electrodes and generally
non-conductive.
[0036] A second electrode assembly disposed on the second face of
the second ceramic element positioned asymmetrically with respect
to the first electrode assembly of the second ceramic element. The
second electrode assembly has at least two electrically isolated
electrodes separated by a non-conducting region and a plurality of
tabs extending along the sidewall of the second ceramic member
towards its first face.
[0037] A plurality of non-conductive tab receiving regions are
disposed on the second face of the second ceramic member, where the
tab receiving regions are free from electrodes and generally
non-conductive. The tab receiving regions of the second face are
axially aligned with the plurality of tabs of the first electrode
assembly and the non-conductive tab regions of the first face are
axially aligned with the plurality of tabs of the second electrode
assembly.
[0038] In keeping with the invention, the first ceramic member is
stacked with the second ceramic member such that the second face of
the first ceramic member is substantially parallel with the first
face of the second ceramic member and at least one of the plurality
of tabs of the second electrode assembly of the first ceramic
element is axially aligned with at least one of the plurality of
tabs of the first electrode assembly of the second ceramic
element.
[0039] In still another embodiment, the invention is directed to a
method of constructing a multilayer ceramic core transformer using
transformer elements. In accordance with the inventive method,
first and second ceramic elements are selected. Each ceramic
element comprises a ceramic member of substantially uniform
thickness, with first and second opposing faces and a sidewall.
Each ceramic element has a first electrode assembly disposed on its
first face and a second electrode assembly disposed on its second
face. The first electrode assembly includes at least two
electrically isolated electrodes separated by a non-conducting
region and a plurality of tabs extending along the sidewall of the
ceramic member towards the second face.
[0040] The ceramic member also has a plurality of non-conductive
tab receiving regions disposed on its first face. The tab receiving
regions are free from electrodes and generally non-conducting.
[0041] The second electrode assembly is disposed on the second face
and positioned asymmetrically with respect to the first electrode
assembly. The second electrode assembly has at least two
electrically isolated electrodes separated by a non-conducting
region and a plurality of tabs extending along the sidewall of said
ceramic member towards its first face. A plurality of
non-conductive tab receiving regions are disposed on the second
face of the ceramic member. The tab receiving regions are free from
electrodes and generally non-conductive. However, the
non-conductive tab receiving regions of the second face are axially
aligned with the plurality of tabs of the first electrode assembly
and the non-conductive tab regions of the first face are axially
aligned with the plurality of tabs of the second electrode
assembly.
[0042] In keeping with the inventive method, the first and second
ceramic elements are arranged in a stacked configuration such that
the electrode assembly of the second face of the first ceramic
element is coincident with the electrode assembly of first face of
the second ceramic element. The electrodes of the second face of
the first ceramic element are bonded to opposing electrodes of the
first face of the second ceramic element. In some embodiments they
may be electrically conductively bonded. At least one of the tabs
of the first electrode assembly of the first ceramic element is
electrically connected to at least one of the tabs of the second
electrode assembly of the second ceramic element to form an input
or an output.
V. BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1A illustrates a prior piezoelectric transformer.
[0044] FIG. 1B depicts a cutaway view of the piezoelectric
transformer of FIG. 1a taken along line BB'.
[0045] FIG. 2A shows a prior piezoelectric transformer.
[0046] FIG. 2B depicts an embodiment of the piezoelectric
transformer of FIG. 2a.
[0047] FIG. 3A is a top view of a modular slat in accordance with
the invention
[0048] FIG. 3B shows a bottom view of the modular slat of FIG.
3a.
[0049] FIG. 3C illustrates a top view of a modular slat in
accordance with an embodiment of the invention.
[0050] FIG. 3D depicts a cutaway view of the modular slat of FIG.
3C along line AA'.
[0051] FIG. 3E depicts a cutaway view of the modular slat of FIG.
3C along line BB'.
[0052] FIG. 3F illustrates a perspective view of a modular slat in
accordance with an embodiment of the invention.
[0053] FIG. 3G shows a top view of a modular slat in accordance
with an embodiment of the invention.
[0054] FIG. 3H depicts a cutaway view of the modular slat of FIG.
3G along line AA'.
[0055] FIG. 3I illustrates a cutaway view of the modular slat of
FIG. 3G along line BB'
[0056] FIG. 3J shows a top view of a modular slat in accordance
with another embodiment of the invention.
[0057] FIG. 3K depicts a cutaway view of the modular slat of FIG.
3J along line AA'.
[0058] FIG. 3L shows a cutaway view of the modular slat of FIG. 3J
along line BB'.
[0059] FIG. 4A illustrates a top view of a modular slat in
accordance with still another embodiment of the invention.
[0060] FIG. 4B shows a bottom view of the modular slat of FIG.
4A.
[0061] FIG. 4C depicts a top view of a modular slot according to
yet another embodiment of the invention.
[0062] FIG. 4D depicts a cutaway view of the modular slat of FIG.
4C along line AA'.
[0063] FIG. 4E shows a cutaway view of the modular slat of FIG. 4C
along line BB'.
[0064] FIG. 4F illustrates a perspective view of a modular slat in
accordance with an embodiment of the invention.
[0065] FIG. 4G shows a top view of a modular slat in accordance
with still another embodiment of the invention.
[0066] FIG. 4H illustrates a cutaway view of the modular slat of
FIG. 4G along line AA'.
[0067] FIG. 4I depicts a cutaway view of the modular slat of FIG.
4G along line BB'.
[0068] FIG. 4J shows a top view of a modular slat in accordance
with still a further embodiment of the invention.
[0069] FIG. 4K depicts a cutaway view of the modular slat of FIG.
4J along line AA'.
[0070] FIG. 4L shows a cutaway view of the modular slat of FIG. 4J
along line BB'.
[0071] FIG. 5 illustrates an embodiment of a parallel in/parallel
out two layer autonomic transformer.
[0072] FIG. 6 depicts an embodiment of a parallel input/serial
output two layer autonomic transformer.
[0073] FIG. 7 shows an embodiment of a serial input/parallel output
two layer autonomic transformer.
[0074] FIG. 8 shows an embodiment of a parallel input/parallel
output four layer autonomic transformer.
[0075] FIG. 9 illustrates an embodiment of a parallel input/serial
output four layer autonomic transformer.
[0076] FIG. 10 depicts an embodiment of a serial input/parallel
output four layer autonomic transformer.
[0077] FIG. 11 depicts an embodiment of a multilayer autonomic
transformer.
VI. DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION
[0078] The invention is generally directed to modular ceramic
elements generally used in the construction of ceramic transformers
and novel embodiments of ceramic transformers themselves. Ceramic
elements in accordance with the invention comprise ceramic
transformer core that is a voltage transformer constructed from one
or more "slats" of common planar shape; a "slat" being a uniformly
thick dielectric ceramic that is sufficiently symmetric to allow
resonant vibration without introduction of significant higher order
harmonics and whose first and second faces are provided with an
electrode pattern. Dependent upon the final transformer
construction requirements, the respective electrode patterns on the
first and second faces of a slat can be disposed both symmetrically
and non-symmetrically. Each such slat that comprises a ceramic
transformer core can be poled either uniformly or non-uniformly as
dependent upon the transformer requirements.
[0079] Suitable planar geometries can include discs, annuli, or
substantially flat squares where an individual slat is normally
manufactured from material that is capable of providing both a
direct effect of mechanical to electrical coupling and converse
electrical to mechanical effect. Such materials include, but are
not limited to, single crystal, piezoelectric ceramic,
flexoelectric, or relaxor ferroelectric materials.
Ceramic Element "Slats"
[0080] In accordance with the invention, a plurality of different
types of modular, reconfigurable ceramic elements or slats are
disclosed that, taken individually or in combination, may form step
up and/or step down ceramic transformers.
Type I-III Ceramic Elements
[0081] Turning to specific embodiments of the invention, a Type I
modular ceramic element includes a ceramic core 70 that is
preferably non-symmetrically electroded on its top surface and
bottom surface. As illustrated in FIG. 3A, the top surface 1
incorporates an electrode pattern that provides for three
physically separated electrodes 3, 4, and 5 that are separated by
insulation regions 6 and 7 which may be bare non-electroded
material or interposed non-conductive material such as urethane
based epoxy, electronics potting material, or simply an air gap.
Electrode 3 includes a band of electrode material that extends
along the outer boundary of the top surface 1 of the ceramic core
70 and includes a discontinuity 10. Electrode 3 further includes a
tab 18 extending downward in the direction of the negative z-axis
and abutting ceramic core 70. In some embodiments, tab 18 extends
along only a portion of sidewall 14 and does not reach the bottom
surface 30 of ceramic core 70. Electrode 3 includes cutouts or tab
receiving regions 8 and 9 which in some embodiments may be filled
in with non-conductive material. As illustrated, cutout 8 is
positioned 90.degree. from tab 18. Cutout 9 is disposed about
90.degree. from cutout 8 and about 180.degree. from tab 18. The
tabs and cutouts are so positioned to align with respective tabs
and cutouts from the bottom surface 30 to facilitate
interconnection of multiple modular ceramic elements.
[0082] Electrode 5 is substantially concentric with electrode 3 and
includes a central region 11 having a leg 12 extending to the outer
radius/edge of ceramic core 70 through discontinuity 10. To provide
a connection mechanism for electrode 5, tab 111 extends
perpendicularly from the end of leg 12 and abuts sidewall 14 of
ceramic core 70. In some embodiments, tab 111 extends along only a
portion of sidewall 14 and does not reach the bottom surface 30, as
best shown in FIG. 3F. In other embodiments, tab 111 extends along
sidewall 14 to the bottom surface 30.
[0083] Electrode 4 is disposed between electrode 3 and 5 and
includes a band that traces the outer edge of central region 11 and
includes first and second legs 15 and 16 that extend to the edge of
ceramic core 70 through discontinuity 10. To provide a connection
mechanism for electrode 4, at least one of first and second legs 15
and 16 includes a tab 17 that extends from the end of at least one
of legs 15 and 16, preferably perpendicularly, along the sidewall
14 of ceramic core 70. In some embodiments, tab 17 extends along
only a portion of sidewall 14 and does not reach the bottom surface
30 as best shown in FIG. 3F.
[0084] Insulation region 6 electrically isolates electrode regions
4 and 5 and insulation region 7 electrically isolates electrode
regions 3 and 4.
[0085] Turning to FIG. 3B, it depicts bottom surface 30 which
incorporates an electrode pattern that provides for three
physically separated electrodes 46, 47, and 48 that are separated
by insulation regions 41 and 42 which may be bare non-electroded
material or interposed non-conductive material. Electrode 46
includes a band of electrode material that extends along the outer
boundary of the bottom surface 30 of ceramic core 70 and includes a
discontinuity 34. The discontinuity 34 of electrode 46 is offset
from the discontinuity 10 of electrode 3 by about 180.degree..
Electrode 46 further includes a tab 19 that is axially aligned with
cutout 9 and extends upward in the direction of the positive z-axis
from electrode 46 along sidewall 14 of ceramic core 70 towards
cutout 9. In some embodiments, tab 19 extends along only a portion
of sidewall 14 and does not reach the top surface 1 of ceramic core
70. Electrode 46 includes cutouts 43 and 44 which in some
embodiments may be filled in with nonconductive material. As
illustrated, cutout 44 is positioned about 90.degree. from tab 19.
While cut out 43 is disposed about 90.degree. from cutout 44 and
about 180.degree. from tab 19.
[0086] Electrode 48 is substantially concentric with electrode 46
and includes a central region 36 having a leg 38 extending to the
outer radius/edge of ceramic core 70 through discontinuity 34. To
provide a connection mechanism for electrode 48, tab 110 is axially
aligned with cutout region 8 and extends perpendicularly from the
end of leg 38 towards cut out region 8 and abuts sidewall 14 of
ceramic core 70. In some embodiments, tab 110 extends along only a
portion of sidewall 14 and does not reach top surface 1 as best
shown in FIG. 3E.
[0087] Electrode 47 is disposed between electrode 46 and 48 and
includes a band that traces the outer edge of central region 36 and
includes first and second legs 50 and 51 that extend to the edge of
ceramic core 70 through discontinuity 34. To provide a connection
mechanism for electrode 47, at least one of first and second legs
50 and 51 includes a tab 105 that extends from the end of the at
least one of legs 50 and 51, preferably perpendicularly, along the
sidewall 14 of ceramic core 70. In some embodiments, tab 105
extends along only a portion of sidewall 14 and does not reach top
surface 1.
[0088] Insulation region 41 electrically isolates electrodes 47 and
48 and insulation region 42 electrically isolates electrodes 46 and
47.
[0089] In accordance with an aspect of the invention, ceramic core
70 may be poled to create capacitive regions between pairs of
non-symmetric top and bottom electrodes. In one embodiment, as
illustrated in FIGS. 3C, 3D and 3E, ceramic core 70 is uniformly
poled in the positive z-axis direction across the thickness of
ceramic core 70 as shown by the arrows. This uniform poling creates
capacitive regions between pairs of (non-symmetric) top and bottom
electrodes 48 and 5, 47 and 4, and 46 and 3.
[0090] In still another embodiment, sometimes referred to as a Type
II ceramic element, ceramic core 70 is non-uniformly transversely
poled in both the positive and negative z-axis direction across the
thickness of ceramic core 70. As shown in FIGS. 3G, 3H and I, the
poling of electrode pairs 3 and 46 and 4 and 47 is taken in the
positive z-axis direction from bottom surface 30 to top surface 1.
The poling of electrode pair 5 and 48 is taken in the negative
z-axis from top surface 1 to bottom surface 30.
[0091] In yet another embodiment, as illustrated in FIGS. 3J, 3K
and 3L, sometimes referred to as a Type III ceramic element,
ceramic core 70 is uniformly poled in the negative z-axis direction
across the thickness of ceramic core 70 as shown by the arrows.
This uniform poling creates capacitive regions between pairs of
(non-symmetric) top and the bottom electrodes 48 and 5, 47 and 4,
and 46 and 3.
Type IV, V and VI Ceramic Elements
[0092] In accordance with a further embodiment, a ceramic element
sometimes referred to as a Type IV ceramic element is described. As
illustrated in FIG. 4A, the top surface 200 of ceramic core 270
incorporates an electrode pattern that provides for two physically
separated electrodes 202 and 204 that are separated by an
insulation region 206 which may be bare non-electroded material or
interposed non-conductive material. Electrode 202 includes a band
of electrode material that extends along the outer boundary of the
top surface 200 of the ceramic core 270 and includes a
discontinuity 208. Electrode 202 further includes a tab 210
extending downward in the direction of the negative z-axis and
abutting ceramic core 270. In some embodiments, tab 210 extends
along only a portion of sidewall 242 and does not reach the bottom
surface 230 of ceramic core 270. Electrode 202 includes cutouts 212
and 214 which in some embodiments may be filled in with
non-conductive material. As illustrated, cutout 212 is positioned
about 90.degree. from tab 210. Cut out 214 is disposed about
90.degree. from cutout 212 and about 180.degree. from tab 210. The
tabs and cutouts are so positioned to align with respective tabs
and cutouts from the bottom surface to facilitate interconnection
of multiple modular ceramic elements.
[0093] Electrode 204 is substantially concentric with electrode 202
and includes a central region 216 having a leg 218 extending to the
outer radius/edge of ceramic core 270 through discontinuity 208. To
provide a connection mechanism for electrode 204, tab 220 extends
perpendicularly from the end of leg 12 and abuts the sidewall 242
of ceramic core 270 as illustrated in FIG. 4D. In some embodiments,
tab 220 extends along only a portion of the sidewall and does not
reach the bottom surface 230 of ceramic core 270.
[0094] Insulation region 206 electrically isolates electrodes 202
and 204 from one another.
[0095] Turning to FIG. 4B, it depicts bottom surface 230 which
incorporates an electrode pattern that provides for two physically
separated electrodes 232 and 234 that are separated by an
insulation region 236 which may be bare non-electroded material or
interposed non-conductive material. Electrode 232 includes a band
of electrode material that extends along the outer boundary of the
bottom surface 230 of ceramic core 270 and includes a discontinuity
238. The discontinuity 238 of electrode 232 is offset from the
discontinuity 208 of electrode 202 by about 180.degree.. Electrode
232 further includes a tab 240 that is axially aligned with cut out
214 and extends upward, in the direction of the positive z-axis,
from electrode 232 along sidewall 242 of ceramic core 270 towards
cutout 214. In some embodiments, tab 240 extends along only a
portion of sidewall 242 and does not reach the top surface 200 of
ceramic core 270. Electrode 232 includes cutouts 244 and 246 which
in some embodiments may be filled in with non-conductive material.
As illustrated, cutout 244 is positioned about 90.degree. from tab
240. While cutout 246 is disposed about 90.degree. from cutout 244
and about 180.degree. from tab 240.
[0096] Electrode 234 is substantially concentric with electrode 232
and includes a central region 248 having a leg 250 extending to the
outer radius/edge of ceramic core 270 through discontinuity 238. To
provide a connection mechanism for electrode 234, tab 252 is
axially aligned with cutout region 212 and extends perpendicularly,
in the direction of the positive z-axis, from the end of leg 250
towards cutout 212 and abuts sidewall 242 of ceramic core 270. In
some embodiments, tab 252 extends along only a portion of sidewall
242 and does not reach top surface 200.
[0097] Insulation region 236 electrically isolates electrodes 232
and 234 from one another.
[0098] Likewise, tab 210 is axially aligned with cutout region 246
and extends perpendicularly, in the direction of the negative
z-axis, from electrode 202 towards cut out region 246 and abuts
sidewall 242 of ceramic core 270. In some embodiments, tab 210
extends along only a portion of sidewall 242 and does not reach top
surface 230.
[0099] In accordance with an aspect of the invention, ceramic core
270 may be poled to create capacitive regions between pairs of
non-symmetric top and bottom electrodes. In one embodiment, as
illustrated in FIGS. 4C, 4D and 4E, ceramic core 270 is uniformly
poled in the positive z-axis direction across the thickness of
ceramic core 270 as shown by the arrows. This uniform poling
creates capacitive regions between pairs of (non-symmetric) top and
bottom electrodes 202 and 232 and 204 and 234.
[0100] In another embodiment, sometimes referred to as a Type V
ceramic element, ceramic core 270 is non-uniformly transversely
poled in both the positive and negative z-axis direction across the
thickness of ceramic core 270. As shown in FIGS. 4G, 4H and 4I, the
poling of electrode pairs 202 and 232 is taken in the positive
z-axis direction from bottom surface 230 to top surface 200. The
poling of electrode pair 204 and 234 is taken in the negative
z-axis direction from top surface 200 to bottom surface 230.
[0101] In yet another embodiment, as illustrated in FIGS. 4J, 4K
and 4L, sometimes referred to as a Type VI ceramic element, ceramic
core 270 is uniformly poled in the negative z-axis direction across
the thickness of ceramic core 270 as shown by the arrows. This
uniform poling creates capacitive regions between pairs of
(non-symmetric) top and the bottom electrodes 202 and 232, and 204
and 234, respectively.
[0102] It should be noted that the Type I through Type III ceramic
elements are comparable, and effectively cross compatible, with the
Type IV through Type VI elements, respectively. The Type I through
Type III elements contain an auxiliary output electrode pair,
typically utilized for autonomic feedback or an additional output.
The Type IV through Type VI elements contain no auxiliary output
electrode pair, but are effectively comparable to the Type I
through Type III. For example, a Type I ceramic element utilized in
the two layer parallel input/parallel output transformer of FIG. 5,
could be replaced with a Type IV ceramic element. The resultant
stacked transformer will sacrifice its auxiliary or autonomic
output, but remain a functioning embodiment of the invention.
[0103] In keeping with an aspect of the invention, each of the
above described types of ceramic elements may be modularly stacked
in various combinations to form autonomic transformers.
Additionally, each of the described ceramic elements may be
implemented as either autonomic or general purpose piezoelectric
transformers in a standalone configuration. Exemplary combinations
of such transformers are depicted in the figures as described
below.
Autonomic Transformer Embodiments
Parallel In/Parallel Out--Two Stack
[0104] Turning to FIG. 5, it depicts an embodiment of the invention
comprising a two-layer parallel input/parallel output autonomic
transformer. A Type VI ceramic element 306 is arranged beneath a
Type I ceramic element 301 such that the top surface 200 of ceramic
element 306 is parallel with the bottom surface 30 of Type I
ceramic element 301. Additionally, the Type VI ceramic element 306
is arranged such that its electrode tab 210 is axially aligned with
the electrode tab 19 of Type I ceramic element 301. This alignment
ensures the electrode pattern of the top surface 200 of Type VI
ceramic element 306 is coincident with the electrode pattern of
bottom surface 30 of Type I ceramic element 301. An electrically
conductive adhesive 310 is used to bond the ceramic elements 301
and 306 across the coincident electrode boundaries, such that
coincident electrode pairs 202 and 46, 48 and 204, and 46 and 202
are connected electrically. In some embodiments, the electrically
conductive adhesive 310 may be anisotropically conductive in the
z-axis to prevent electrical connection between coincident
electrode pairs during manufacture. Additionally, in embodiments
using anisotropic adhesive, the entire planar surface between the
ceramic elements may be covered with said anisotropic adhesive,
creating a persistent continuous layer of material between the
elements.
[0105] In this embodiment, electrodes 3 and 232 become the first
input terminal to the transformer. Electrodes 46 and 202, now
electrically connected by the conductive adhesive 310, become the
second input terminal to the transformer. An electrically
conductive material 320, typically solder, can be used to
electrically connect tabs 18 and 240 together, thus providing a
simple method for electrically connecting electrodes 3 and 232.
This configuration results in an electrically parallel connection
of the input side capacitive regions of ceramic elements 301 and
306.
[0106] The first output terminal includes electrodes 5 and 234. The
second output terminal includes electrodes 48 and 204, now
electrically connected by conductive adhesive 310. An electrically
conductive material 321, typically solder, can be used to
electrically connect tabs 111 and 252 together, thus providing a
simple method for electrically connecting electrodes 5 and 234.
This configuration results in an electrically parallel connection
of the output side capacitive regions of ceramic elements 301 and
306.
[0107] Electrode 4 and 47 of Type I ceramic element 301 become the
first and second terminals for the autonomic auxiliary output of
the transformer, respectively.
[0108] The parallel input/parallel output configuration of ceramic
elements in this embodiment will typically result in a step-down or
near unity voltage transform ratio. The parallel input
configuration will result in an increased input capacitance when
compared to the capacitance of a single element. When operated at
its static resonant frequency, an increase in input capacitance
results in decreased input impedance. Likewise, the parallel output
configuration effectively increases the output capacitance, thus
decreasing the output impedance.
Parallel In/Serial Out--Two Stack
[0109] Turning to FIG. 6, it depicts an embodiment of the invention
demonstrating a two-layer parallel input/serial output autonomic
transformer. In this embodiment a Type II ceramic element 302 and a
Type VI ceramic element 306 are bonded in a manner as described for
the two-layer parallel in/parallel out case, depicted in FIG. 5,
where the Type I ceramic element 301, of FIG. 5, is replaced with a
Type II ceramic element, as depicted in FIG. 6.
[0110] Electrodes 3 and 232 become the first input terminal to the
transformer. Electrodes 46 and 202, again electrically connected by
the conductive adhesive 310, become the second input terminal to
the transformer. An electrically conductive material 320, typically
solder, can be used to electrically connect tabs 18 and 240
together, thus providing a simple method for electrically
connecting electrodes 3 and 232. This configuration results in an
electrically parallel connection of the input side capacitive
regions of ceramic elements 301 and 306.
[0111] In this embodiment, the first output terminal is taken from
electrode 234. The second output terminal is taken from electrode
5. Additionally, tab 111 of electrode 5 and tab 252 of electrode
234 are left electrically isolated. This configuration results in
an electrically serial connection of the output side capacitive
regions of ceramic elements 301 and 306.
[0112] Electrode 4 and 47 of Type I ceramic element 301 become the
first and second terminals for the autonomic auxiliary output of
the transformer, respectively.
[0113] The parallel input/serial output configuration of ceramic
elements in this embodiment will typically result in a step-up
voltage transform ratio. The parallel input configuration will
result in an increased input capacitance when compared to the
capacitance of a single element. When operated at its static
resonant frequency, an increase in input capacitance results in
decreased input impedance. Conversely, the serial output
configuration effectively decreases the output capacitance, thus
increasing the output impedance.
Serial In/Parallel Out--Two Stack
[0114] Turning to FIG. 7, it depicts an embodiment of the invention
demonstrating a two-layer serial input/parallel output autonomic
transformer. In this embodiment a Type I ceramic element 301 and a
Type V ceramic element 305 are bonded in a manner as described for
the two-layer parallel in/parallel out case, depicted in FIG. 5,
where the Type VI ceramic element 306, of FIG. 5, is replaced with
a Type V ceramic element 305, as depicted in FIG. 7.
[0115] In this embodiment, the first input terminal is taken from
electrode 3. The second input terminal is taken from electrode 232.
Additionally, tab 18 of electrode 3 and tab 240 of electrode 232
are left electrically isolated. This configuration results in an
electrically serial connection of the input side capacitive regions
of ceramic elements 301 and 305.
[0116] The first output terminal includes electrodes 5 and 234. The
second output terminal includes electrodes 48 and 204, now
electrically connected by conductive adhesive 310. An electrically
conductive material 321, typically solder, can be used to
electrically connect tabs 111 and 252 together, thus providing a
simple method for electrically connecting electrodes 5 and 234.
This configuration results in an electrically parallel connection
of the output side capacitive regions of ceramic elements 301 and
305.
[0117] Electrode 4 and 47 of Type I ceramic element 301 become the
first and second terminals for the autonomic auxiliary output of
the transformer, respectively.
[0118] The serial input/parallel output configuration of ceramic
elements in this embodiment will typically result in a step-down
voltage transform ratio. The serial input configuration will result
in a decreased input capacitance when compared to that of a single
element. When operated at its static resonant frequency, a decrease
in input capacitance results in increased input impedance.
Conversely, the parallel output configuration effectively increases
the output capacitance, thus decreasing the output impedance.
Parallel In/Parallel Out--Four Stack
[0119] Turning to FIG. 8, it depicts an embodiment of the invention
demonstrating a four-layer parallel input/parallel output autonomic
transformer. The Type VI ceramic element 503 is concentrically
arranged beneath ceramic element 501, with its top surface parallel
to the bottom surface of ceramic element 501, such that its
electrode tab 441 is axially aligned with the electrode tab 422 of
ceramic element 501. The Type IV ceramic element 505 is
concentrically arranged beneath ceramic element 503, with its top
surface parallel to the bottom surface of ceramic element 503, such
that its electrode tab 462 is axially aligned with the electrode
tab 441 of ceramic element 503. Likewise, the second Type VI
ceramic element 507 is concentrically arranged beneath ceramic
element 505, with its top surface parallel to the bottom surface of
ceramic element 505, such that its electrode tab 481 is axially
aligned with the electrode tab 462 of ceramic element 505.
[0120] An electrically conductive adhesive 310 is used to bond
ceramic elements 501, 503, 505 and 507 across their respective
coincident electrode boundaries, such that coincident electrode
pairs 412 and 431, 414 and 433, 432 and 451, 434 and 453, 452 and
471, and 454 and 473 are connected electrically. In some
embodiments, the electrically conductive adhesive 310 may be
anisotropically conductive in the z-axis to prevent electrical
connection between coincident electrode pairs during manufacture.
Additionally, in embodiments using anisotropic adhesive, the entire
planar surface between the ceramic elements may be covered with
said anisotropic adhesive, creating a persistent continuous layer
of material between the elements.
[0121] In this embodiment, electrodes 411, 432, 451 and 472 become
the first input terminal to the transformer. Electrodes 412, 431,
452 and 471 become the second input terminal to the transformer. An
electrically conductive material 520 can be used to electrically
connect tabs 421, 442, 461 and 482, thus providing a simple method
for electrically connecting the first input terminal electrodes.
Likewise, an electrically conductive material 521 can be used to
electrically connect tabs 422, 441, 462 and 481, thus providing a
simple method for electrically connecting the second input terminal
electrodes. This configuration results in an electrically parallel
connection of the input side capacitive regions of ceramic elements
501, 503, 505 and 507.
[0122] The first output terminal includes electrodes 413, 434, 453,
and 474. The second output terminal includes electrodes 414, 433,
454 and 473. An electrically conductive material 523 can be used to
electrically connect tabs 423, 444, 463 and 484, thus providing a
simple method for electrically connecting the first output terminal
electrodes. Likewise, an electrically conductive material 522 can
be used to electrically connect tabs 424, 443, 464 and 483, thus
providing a simple method for electrically connecting the second
output terminal electrodes. This configuration results in an
electrically parallel connection of the output side capacitive
regions of ceramic elements 501, 503, 505 and 507.
[0123] Electrode 415 and 416 of Type I ceramic element 501 become
the first and second terminals for the autonomic auxiliary output
of the transformer, respectively.
[0124] The parallel input/parallel output configuration of ceramic
elements in this embodiment will typically result in a step-down or
near unity voltage transform ratio.
Parallel In/Serial Out--Four Stack
[0125] Turning to FIG. 9, it depicts an embodiment of the invention
demonstrating a four-layer parallel input/serial output autonomic
transformer. In this embodiment a Type III ceramic element 501,
Type V ceramic element 503, Type VI ceramic element 505 and a Type
V ceramic element 507 are bonded in a manner as described for the
four-layer parallel in/parallel out case, depicted in FIG. 8, where
the stack arrangement is now Type III, Type V, Type VI, Type V,
from top to bottom.
[0126] In this embodiment, electrodes 411, 432, 451 and 472 become
the first input terminal to the transformer. Electrodes 412, 431,
452 and 471 become the second input terminal to the transformer. An
electrically conductive material 520 can be used to electrically
connect tabs 421, 442, 461 and 482, thus providing a simple method
for electrically connecting the first input terminal electrodes.
Likewise, an electrically conductive material 521 can be used to
electrically connect tabs 422, 441, 462 and 481, thus providing a
simple method for electrically connecting the second input terminal
electrodes. This configuration results in an electrically parallel
connection of the input side capacitive regions of ceramic elements
501, 503, 505 and 507.
[0127] In this embodiment, the first output terminal is taken from
electrode 474. The second output terminal is taken from electrode
413. This configuration results in an electrically serial
connection of the output side capacitive regions of ceramic
elements 501, 503, 505 and 507.
[0128] Electrode 415 and 416 of Type III ceramic element 501 become
the first and second terminals for the autonomic auxiliary output
of the transformer, respectively.
[0129] The parallel input/serial output configuration of ceramic
elements in this embodiment will typically result in a step-up
voltage transform ratio.
Serial In/Parallel Out--Four Stack
[0130] Turning to FIG. 10, it depicts an embodiment of the
invention demonstrating a four-layer serial input/parallel output
autonomic transformer. In this embodiment a Type I ceramic element
501, Type V ceramic element 503, Type IV ceramic element 505 and a
Type V ceramic element 507 are bonded in a manner as described for
the four-layer parallel in/parallel out case, depicted in FIG. 8,
where the stack arrangement is now Type I, Type V, Type IV, Type V,
from top to bottom.
[0131] In this embodiment, the first input terminal is taken from
electrode 411. The second input terminal is taken from electrode
472. This configuration results in an electrically serial
connection of the output side capacitive regions of ceramic
elements 501, 503, 505 and 507.
[0132] The first output terminal includes electrodes 413, 434, 453,
and 474. The second output terminal includes electrodes 414, 433,
454 and 473. An electrically conductive material 523 can be used to
electrically connect tabs 423, 444, 463 and 484, thus providing a
simple method for electrically connecting the first output terminal
electrodes. Likewise, an electrically conductive material 522 can
be used to electrically connect tabs 424, 443, 464 and 483, thus
providing a simple method for electrically connecting the second
output terminal electrodes. This configuration results in an
electrically parallel connection of the output side capacitive
regions of ceramic elements 501, 503, 505 and 507.
[0133] Electrode 415 and 416 of Type I ceramic element 501 become
the first and second terminals for the autonomic auxiliary output
of the transformer, respectively.
[0134] The serial input/parallel output configuration of ceramic
elements in this embodiment will typically result in a step-down
voltage transform ratio.
N-Stack
[0135] In keeping with the aspect of the invention, any number of
modular ceramic elements may be used in numerous combinations and
count to form autonomic capable transformers. FIG. 11 depicts an
embodiment of a method for modular stacking of ceramic elements.
Ceramic elements 601 and 602 are selected based on application
needs, where the selection of ceramic element type and arrangement
provide means for controlling the input and output impedance
characteristics of the autonomic transformer by variation of
series/parallel electrical connection. Therefore, in FIG. 11, any
number of additional ceramic cores or combinations of stacked
ceramics cores can be integrated into the stack within area 610. It
is of note that any number of autonomic ready, Type I through Type
III, slats can be used within a single stack, providing additional
electrically isolated voltage outputs.
[0136] As used above "substantially," "generally," "relatively" and
other words of degree are relative modifiers intended to indicate
permissible variation from the characteristic so modified. It is
not intended to be limited to the absolute value or characteristic
which it modifies but rather possessing more of the physical or
functional characteristic than its opposite, and preferably,
approaching or approximating such a physical or functional
characteristic.
[0137] Although the present invention has been described in terms
of particular embodiments, it is not limited to those embodiments.
Alternative embodiments, examples, and modifications which would
still be encompassed by the invention may be made by those skilled
in the art, particularly in light of the foregoing teachings.
[0138] Those skilled in the art will appreciate that various
adaptations and modifications of the embodiments described above
can be configured without departing from the scope and spirit of
the invention. Therefore, it is to be understood that, within the
scope of the appended claims, the invention may be practiced other
than as specifically described herein.
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