Transformer and its transformer frame

Abstract

A transformer includes a transformer frame, a primary winding, a secondary winding, and a magnetic core. The transformer frame includes a first winding section, a second winding section spaced from the first winding section, and a lead-out section connected to the first winding section. The second winding section has a plurality of stepped surfaces formed within its winding region. The primary winding is disposed on the first winding section and leads out from the lead-out section. The secondary winding includes a plurality of U-shaped conductors, the number of which corresponds to the number of stepped surfaces formed within the second winding section. The U-shaped conductors are electrically connected via a circuit board. The magnetic core is disposed on the transformer frame. This transformer can be used for high power applications and possesses leakage inductance balancing characteristics.

Description

Technical Field

[0001] This invention provides a transformer and its transformer frame, particularly a transformer and its transformer frame that can be used for high power and has balanced leakage inductance. Prior Technology

[0002] Transformers with leakage inductance balance already exist, but to achieve leakage inductance balance, existing transformer structures all require the addition of magnetic conductive components to the existing transformer structure. The leakage inductance balance is achieved through these magnetic conductive components.

[0003] Adding magnetic conductors not only complicates the transformer's structure but also increases the number of manufacturing steps. The inclusion of magnetic conductors also increases the overall manufacturing cost of the transformer. Summary of the Invention

[0004] The main objective of this invention is to solve the problem arising from the need to add magnetic conductive components to achieve leakage inductance balance in conventional transformer structures.

[0005] To achieve the above objectives, the present invention provides a transformer, comprising a transformer frame, a primary winding, a secondary winding, and a magnetic core. The transformer frame includes a first winding portion, a second winding portion spaced apart from the first winding portion, and a lead-out portion connected to the first winding portion. The second winding portion has a plurality of stepped surfaces formed within its winding region. The primary winding is disposed on the first winding portion and leads out from the lead-out portion. The secondary winding includes a plurality of U-shaped conductors, the number of which corresponds to the number of stepped surfaces formed within the second winding portion. The U-shaped conductors are disposed corresponding to the stepped surfaces and are electrically connected via a circuit board. The magnetic core is disposed on the transformer frame.

[0006] In one embodiment, one of the stepped surfaces closest to the first winding portion is the highest among the stepped surfaces.

[0007] In one embodiment, the height difference between any two successors of the stepped surfaces is greater than the thickness of each of the U-shaped conductors, so that the U-shaped conductors do not contact each other on the transformer frame.

[0008] In one embodiment, the second winding portion has a plurality of fixing blocks formed in the winding area. The fixing blocks are respectively located on two opposite sides of the second winding portion. Each of the fixing blocks and the stepped surfaces has a plurality of hollow areas formed therein, each providing one of the U-shaped conductors to pass through.

[0009] In one embodiment, the transformer winding frame includes a plurality of partitions disposed between the first winding portion and the second winding portion, the partitions being spaced apart.

[0010] In one embodiment, at least one of the U-shaped conductors is formed by stacking multiple copper sheets.

[0011] In one embodiment, the transformer further includes a cover disposed between the magnetic core and the transformer frame.

[0012] In one embodiment, the cover is formed with an accommodating space, a plurality of faces facing the walls of the accommodating space, and a plurality of limiting ribs respectively provided on two opposite sides of the walls and capable of contacting one of the U-shaped conductors.

[0013] In one embodiment, two of the limiting ribs formed in the wall surfaces directly abut one of the U-shaped conductors.

[0014] In one embodiment, the transformer wire frame includes a support portion that connects to the second winding portion.

[0015] In addition to the foregoing, the present invention also provides a transformer winding frame, comprising a first winding portion, a second winding portion spaced apart from the first winding portion, and an outlet portion connected to the first winding portion. The second winding portion has a plurality of stepped surfaces formed within the winding region.

[0016] In one embodiment, one of the stepped surfaces closest to the first winding portion is the highest among the stepped surfaces.

[0017] In one embodiment, the second winding portion has a plurality of fixing blocks formed in the winding area, the fixing blocks being located on two opposite sides of the second winding portion, and a plurality of hollow areas being formed between each of the fixing blocks and the stepped surfaces.

[0018] In one embodiment, the transformer winding frame includes a plurality of partitions disposed between the first winding portion and the second winding portion, the partitions being spaced apart.

[0019] In one embodiment, the transformer wire frame includes a support portion that connects to the second winding portion.

[0020] Compared with conventional technology, the present invention has the following advantages through the aforementioned technical implementation: The transformer of the present invention does not require additional magnetic conductors; leakage inductance balance is achieved solely through the structural design of the second winding section of the transformer frame and the U-shaped conductors of the secondary winding. The manufacturing process is simple and facilitates automated production, thus reducing manufacturing costs. Simple Explanation of the Diagram

[0021] Figure 1 is an exploded view of the structure of a transformer according to an embodiment of the present invention. Figure 2 is a three-dimensional structural diagram of a transformer with a primary winding and a secondary winding according to an embodiment of the present invention. Figure 3 is a side view of a transformer winding with a primary winding and a secondary winding according to an embodiment of the present invention. Figure 4 is a side view of a transformer line frame according to an embodiment of the present invention. Figure 5 is a top view of a transformer line frame according to an embodiment of the present invention. Figure 6 is a schematic diagram of the transformer wire frame, primary winding, and secondary winding according to an embodiment of the present invention. Figure 7 is a schematic diagram of the structure of a U-shaped conductor according to an embodiment of the present invention. Figure 8 is a schematic diagram of the overall structure of a transformer according to an embodiment of the present invention. Figure 9 is an exploded view of the transformer structure according to an embodiment of the present invention. Figure 10 is a schematic diagram of the assembly of the cover and the transformer frame according to an embodiment of the present invention. Figure 11 is a schematic diagram of the transformer structure from a bottom view according to an embodiment of the present invention. Figure 12 is a schematic diagram of the vertical transformer frame structure of a transformer according to an embodiment of the present invention. Implementation

[0022] The detailed description and technical content of this invention are as follows, with reference to the accompanying drawings:

[0023] Referring to Figures 1 to 4, this invention provides a transformer 20, which can be applied in high-power implementation circuits and possesses leakage inductance balance characteristics. The transformer 20 of this invention includes a transformer frame 30, a primary winding 40, a secondary winding 50, and a magnetic core 60. The transformer frame 30 includes a first winding portion 31, a second winding portion 32 separated from the first winding portion 31, and an output portion 33 connected to the first winding portion 31. Further, the second winding portion 32 of this invention has a plurality of stepped surfaces 321 and 322 formed within the winding region, and these stepped surfaces 321 and 322 have different heights. The primary winding 40 is disposed on the first winding portion 31 and exits through the exit portion 33. In this embodiment, the primary winding 40 is formed by winding wire 41 according to a set number of turns. The two ends of the wire 41 are respectively fixed on the exit portion 33. The wire can be enameled wire or triple-insulated wire, etc., and the present invention does not limit it. On the other hand, the secondary winding 50 includes a plurality of U-shaped conductors 51 and 52. The number of U-shaped conductors 51 and 52 is equal to the number of stepped surfaces 321 and 322 formed on the second winding portion 32. The U-shaped conductors 51 and 52 are provided corresponding to the stepped surfaces 321 and 322. Specifically, each of the stepped surfaces 321 (322) provides only one of the U-shaped conductors 51 (52). The U-shaped conductors 51 and 52 are electrically connected through conductive lines on a circuit board (not shown) to form the winding. Although the U-shaped conductors 51 and 52 are both U-shaped, their detailed dimensions are based on one of the proposed stepped surfaces 321 and 322. Furthermore, the magnetic core 60 is disposed on the transformer frame 30. The magnetic core 60 can be implemented using appropriate configurations according to the design, such as the EE configuration or the EI configuration, and this invention does not limit the configuration of the magnetic core 60.

[0024] Continuing from the above, compared to the conventional structure of transformers with leakage inductance balancing, this invention does not require additional magnetic conductors for leakage inductance balancing. Leakage inductance balancing is achieved solely through the structural design of the second winding portion 32 of the transformer frame 30, and the U-shaped conductors 51 and 52 of the secondary winding 50. The manufacturing process is simple and facilitates automated production. Furthermore, the overall structure of the transformer 20 reduces manufacturing costs.

[0025] Please refer to Figures 3 and 4. In one embodiment, one of the stepped surfaces 321 and 322 closest to the first winding portion 31 is the highest among the stepped surfaces 321 and 322 (i.e., the one labeled 321). On the other hand, in one embodiment, the height difference 71 between any two successive stepped surfaces 321 and 322 is greater than the thickness 511 of each of the U-shaped conductors 51 and 52, so that the U-shaped conductors 51 and 52 do not contact each other on the transformer frame 30 (as shown in Figure 1).

[0026] Please refer to Figures 2 and 5. In one embodiment, the second winding portion 32 has a plurality of fixing blocks 323 and 324 formed within the winding area. These fixing blocks 323 and 324 are located on two opposite sides of the second winding portion 32 (as shown in Figure 5). Each of the fixing blocks 323 (324) has a plurality of hollow areas 325 and 326 formed between it and the stepped surfaces 321 and 322, providing a space for one of the U-shaped conductors 51 and 52 to pass through. The size of these hollow areas 325 and 326 can be set to conform to the shape of one of the U-shaped conductors 51 and 52 to be inserted, so that the U-shaped conductors 51 and 52 can be inserted into the hollow areas 325 and 326 without falling out. In this embodiment, during the manufacturing of the transformer 20, the primary winding 40 can be automatically wound onto the first winding portion 31, and then the U-shaped conductors 51 and 52 are inserted into the hollowed-out areas 325 and 326 to form the secondary winding 50 as shown in Figure 6. Afterwards, the magnetic core 60 and other components are assembled sequentially to complete the transformer 20, as shown in Figure 1.

[0027] Please refer to Figure 4. In one embodiment, the transformer wire frame 30 includes a plurality of partitions 34 and 35 disposed between the first winding portion 31 and the second winding portion 32, and the partitions 34 and 35 are spaced apart.

[0028] Please refer to Figure 7. At least one of the U-shaped conductors 51 and 52 of the present invention can be formed by stacking a plurality of copper sheets 53.

[0029] Referring again to Figure 8, the transformer 20 of the present invention further includes a cover 80 disposed between the magnetic core 60 and the transformer frame 30. The cover 80 is placed on the transformer frame 30 after the primary winding 40 and the secondary winding 50 are installed, but before they are assembled with the magnetic core 60. In one embodiment, the U-shaped conductors 51, 52 of the secondary winding 50 can be assisted in fixing by the cover 80. Referring to Figures 9 to 11, in one embodiment, the cover 80 is formed with an accommodating space 81, and a plurality of walls 82, 83 facing the accommodating space 81, a plurality of opposing limiting ribs 821, 831 are respectively disposed on the walls 82, 83. Specifically, the limiting ribs 821 and 831 need to contact one of the U-shaped conductors 51 and 52 when the enclosure 80 is connected to the transformer frame 30 with the U-shaped conductors 51 and 52, so as to restrict the positioning of one of the U-shaped conductors 51 and 52 on one of the stepped surfaces 321 and 322. Furthermore, the limiting ribs 821 and 831 can apply a pushing force to one of the contacting U-shaped conductors 51 and 52. In this way, manufacturing tolerances of the U-shaped conductors 51 and 52 can be resolved by the limiting ribs 821 and 831. Further, in an extended embodiment, two of the limiting ribs 821 and 831 formed in the wall surfaces 82 and 83 directly abut against one of the U-shaped conductors 51 and 52. Two of the aforementioned wall surfaces 82 and 83 forming the limiting ribs 821 and 831 can also apply a pushing force to one of the contacting U-shaped conductors 51 and 52. Furthermore, the implementation scheme of fixing the U-shaped conductors 51 and 52 with the structure of the cover 80 is not limited to the aforementioned single one, but can be implemented in combination according to implementation requirements. Please refer to Figures 9 and 10 again. In one embodiment, the cover 80 has a plurality of guide ribs 822 and 832 respectively provided on two of the limiting ribs 821 and 831 formed in the wall surfaces 82 and 83. When the cover 80 is installed with the transformer line frame 30, the guide ribs 822 and 832 move in the partitions 34 and 35 to assist in the positioning of the cover 80 during installation.

[0030] Please refer to Figures 1 and 9 in conjunction. In one embodiment, the transformer winding frame 30 includes a support 36 connecting to the second winding portion 32. The support 36 is designed to ensure stability of the transformer winding frame 30 when placed on a circuit board (not shown). It should be understood that the support 36 is not used to provide the secondary winding 50 with leads.

[0031] In summary, the transformer 20 of this invention is not limited to a horizontal transformer structure or a vertical transformer structure. The inventive spirit of this invention can be applied to both horizontal and vertical transformer structures. Figure 12 shows a partial structural schematic diagram of this invention applied to a vertical transformer.

[0032] 20: Transformer 30: Transformer frame 31: First winding section 32: Second winding section 321, 322: Step surfaces 323, 324: Fixed blocks 325, 326: Hollowed-out areas 33: Outbound section 34, 35: partition 36: Support section 40: Primary winding 41: Wire 50: Secondary winding 51, 52: U-shaped conductor 511: Thickness 53: Copper sheet 60: Magnetic core 71: Vertical Distance 80: Cover 81: Storage space 82, 83: Wall 821, 831: Restriction Ribs 822, 832: Guide ribs

Claims

1. A transformer, comprising: a transformer frame including a first winding portion, a second winding portion spaced apart from the first winding portion, and a lead-out portion connected to the first winding portion, the second winding portion having a plurality of stepped surfaces formed in a winding region; a primary winding disposed in the first winding portion and leading out from the lead-out portion; a secondary winding including a plurality of U-shaped conductors, the number of which corresponds to the number of stepped surfaces formed in the second winding portion, the U-shaped conductors being disposed corresponding to the stepped surfaces, the U-shaped conductors being electrically connected via a circuit board; and a magnetic core disposed in the transformer frame; wherein... The height difference between any two of these stepped surfaces is greater than the thickness of each of these U-shaped conductors, so that these U-shaped conductors do not contact each other on the transformer frame.

2. The transformer as described in claim 1, wherein, One of the stepped surfaces closest to the first winding portion is the highest among these stepped surfaces.

3. The transformer as described in claim 1 or 2, wherein, The second winding section has a plurality of fixing blocks formed in the winding area. These fixing blocks are located on two opposite sides of the second winding section. Each of these fixing blocks and the stepped surfaces has a plurality of hollow areas formed therein, each providing a space through which one of the U-shaped conductors passes.

4. The transformer as described in claim 1 or 2, wherein, The transformer frame includes a plurality of partitions disposed between the first winding section and the second winding section, the partitions being spaced apart.

5. The transformer as described in claim 1 or 2, wherein, At least one of these U-shaped conductors is formed by stacking multiple copper sheets.

6. The transformer as described in claim 1 or 2, wherein, The transformer further includes a housing located between the magnetic core and the transformer frame.

7. The transformer as described in claim 6, wherein, The enclosure is formed to have an accommodating space, with a plurality of faces facing the walls of the accommodating space, and a plurality of limiting ribs respectively provided on two opposite sides of the walls and capable of contacting one of the U-shaped conductors.

8. The transformer as described in claim 7, wherein, Two of the limiting ribs formed in these walls directly abut one of the U-shaped conductors.

9. The transformer as described in claim 1 or 2, wherein, The transformer frame includes a support portion that connects to the second winding section.

10. A transformer frame, comprising: a first winding portion; a second winding portion spaced apart from the first winding portion, the second winding portion forming a plurality of stepped surfaces within the winding region, the height difference between any two successive steps being sufficient to ensure that the plurality of U-shaped conductors do not contact each other when arranged corresponding to the steps; and an outlet portion connected to the first winding portion.

11. The transformer frame as described in claim 10, wherein, One of the stepped surfaces closest to the first winding portion is the highest among these stepped surfaces.

12. The transformer line frame as described in claim 10 or 11, wherein, The second winding section has a plurality of fixing blocks formed in the winding area. These fixing blocks are located on two opposite sides of the second winding section, and a plurality of hollow areas are formed between each of the fixing blocks and the stepped surfaces.

13. The transformer line frame as described in claim 10 or 11, wherein, The transformer frame includes a plurality of partitions disposed between the first winding section and the second winding section, the partitions being spaced apart.

14. The transformer line frame as described in claim 10 or 11, wherein, The transformer frame includes a support portion that connects to the second winding section.

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