Transformer device

Abstract

This disclosure discloses a transformer device. This transformer device includes a magnetic core assembly, a primary coil, a secondary coil, and a magnetically conductive adhesive component. The primary coil is disposed within the magnetic core assembly. The secondary coil is disposed within the magnetic core assembly. The magnetically conductive adhesive component is disposed between the primary coil and the secondary coil.

Description

[Technical Field]

[0001] This disclosure relates to a transformer device, and more particularly to a transformer device that can improve leakage inductance. [Previous Technology]

[0002] In the field of power supplies, as the volumetric power density of power supplies increases, the circuitry requires the leakage inductance of a transformer to resonate. The leakage inductance of a transformer is generated through the coupling between its primary and secondary windings. The degree of coupling is negatively correlated with the distance between the primary and secondary windings; that is, the greater the distance, the lower the coupling, and conversely, the higher the leakage inductance. Therefore, to increase the leakage inductance, the design size of the transformer needs to be increased.

[0003] In view of this, how to improve the leakage inductance of a transformer without increasing its size is a direction that practitioners in this field are committed to developing. [Summary of the Invention]

[0004] In view of prior art, this invention discloses a novel transformer device that increases the leakage inductance of the transformer device itself by placing a magnetic adhesive between the primary coil and the secondary coil, thereby eliminating the need to increase the distance between the primary coil and the secondary coil, and thus eliminating the need to increase the size of the transformer device.

[0005] In detail, according to one aspect of this disclosure, a transformer device is provided. This transformer device includes a magnetic core assembly, a primary coil, a secondary coil, and a magnetically conductive adhesive element. The primary coil is disposed in the magnetic core assembly. The secondary coil is disposed in the magnetic core assembly. The magnetically conductive adhesive element is disposed between the primary coil and the secondary coil.

[0006] The above description of the invention is not intended to represent all embodiments or aspects of this disclosure. Rather, the foregoing description is merely an example illustrating some novel aspects and features of this disclosure. Preferred embodiments are provided in conjunction with the accompanying drawings to make the above embodiments and other objects, features, and advantages of this disclosure more apparent. After a detailed description of various embodiments with reference to the accompanying drawings, those skilled in the art will more readily understand other aspects of this disclosure. A brief description of the drawings is provided below.

Implementation Method

[0008] The embodiments of this disclosure will be described in detail below, with reference to the accompanying drawings. In addition to these detailed descriptions, this disclosure can be widely implemented in other embodiments, and any easy substitutions, modifications, or equivalent changes to the described embodiments are included within the scope of this disclosure and are subject to the claims in the following applications. In the description of the specification, many specific details are provided to give the reader a more complete understanding of this disclosure; however, this disclosure may still be implemented even if some or all of these specific details are omitted. Furthermore, well-known common steps or elements are not described in detail to avoid creating unnecessary limitations to this disclosure. Identical or similar elements in the drawings will be represented by the same or similar symbols. It should be noted that the drawings are for illustrative purposes only and do not represent the actual size or quantity of elements unless otherwise specified.

[0009] Please refer to Figure 1, which shows an exploded view of the transformer device 100 in the first state of the disclosed embodiment.

[0010] As shown in Figure 1, the transformer device 100 in the first state may include a magnetic core assembly 110, a primary coil 120, a secondary coil 130, and magnetically conductive adhesive components 140A and 140B. The magnetic core assembly 110 may include a first magnetic core component 111 and a second magnetic core component 112, and the first magnetic core component 111 and the second magnetic core component 112 are symmetrically arranged. The primary coil 120 and the secondary coil 130 are both disposed on the magnetic core assembly 110.

[0011] In this embodiment, two secondary coils 130 are arranged on both sides of the primary coil 120, and a magnetically conductive adhesive element 140A, 140B is provided between the primary coil 120 and each of the two secondary coils 130. As shown in Figure 1, the magnetically conductive adhesive element 140A (or magnetically conductive adhesive element 140B) is located between the primary coil 120 and the secondary coil 130 adjacent to the second magnetic core 112, while the magnetically conductive adhesive element 140B (or magnetically conductive adhesive element 140A) is located between the primary coil 120 and the secondary coil 130 adjacent to the first magnetic core 111. That is, the magnetically conductive adhesive elements 140A, 140B can be attached to the primary coil 120 or the secondary coil 130. In another embodiment, the magnetically conductive adhesive element 140C shown in Figure 2A can also be attached to the primary coil 120 or the secondary coil 130.

[0012] For example, magnetically conductive adhesive components 140A, 140B, and 140C are all attached to the primary coil 120; or, magnetically conductive adhesive components 140A, 140B, and 140C are attached to their respective adjacent secondary coils 130; or, one of the magnetically conductive adhesive components 140A, 140B, and 140C is attached to the primary coil 120, and another is attached to its adjacent secondary coil 130. Therefore, it is not limited to whether the magnetically conductive adhesive components 140A, 140B, and 140C are attached to the primary coil 120 or the secondary coil 130.

[0013] In one embodiment, the primary coil 120 may be a wire winding, a single secondary coil 130 may include multiple stacked metal sheet-like members 131, and the magnetically conductive adhesive members 140A and 140B are ring-shaped structures. Specifically, the magnetically conductive adhesive members 140A and 140B have different shapes; 140A is a closed ring-shaped structure, while 140B is an open ring-shaped structure with a notch. In other embodiments, the magnetically conductive adhesive members attached to the primary coil 120 or the secondary coil 130 may use the same two magnetically conductive adhesive members 140A or the same two magnetically conductive adhesive members 140B; that is, it is not limited to using both magnetically conductive adhesive members 140A and 140B simultaneously.

[0014] In one embodiment, the wire winding of the primary coil 120 has a through hole H1, each metal sheet 131 has a through hole H2 at its center, and the magnetically conductive adhesive members 140A and 140B with annular structures have a through hole H3 at their center. The magnetic core assembly 110 can pass through these through holes H1, H2, and H3 together to fit the primary coil 120, the secondary coil 130, and the magnetically conductive adhesive members 140A and 140B onto the magnetic core assembly 110.

[0015] In detail, in the magnetic core assembly 110, the first magnetic core 111 and the second magnetic core 112 located on the left and right sides respectively have a first protruding post 111P and a second protruding post 112P. When the first protruding post 111P and the second protruding post 112P are assembled, their top surfaces are connected to form a shaft (parallel to the Y-axis in Figure 1). In this way, the first protruding post 111P and the second protruding post 112P pass through the primary coil 120, the secondary coil 130 and the magnetically conductive adhesive 140A, 140B, so that the primary coil 120, the secondary coil 130 and the magnetically conductive adhesive 140A, 140B are sleeved on this shaft. In this state, when the transformer assembly 100 is assembled, the magnetically conductive adhesive parts 140A and 140B can simultaneously contact the primary coil 120 and its adjacent secondary coil 130 to strengthen the fixation of the magnetically conductive adhesive parts in the transformer assembly.

[0016] Please refer to Figures 2A and 2B, which illustrate exploded and assembled schematic diagrams of the transformer device 100 in the second state of the disclosed embodiment. The transformer device 100 in the second state includes a magnetic core assembly 110, a primary coil 120, and a secondary coil 130, and may adopt similar or identical implementation details as described above, which will not be repeated here. The following focuses on describing the distinguishing features of this state.

[0017] Similarly, the transformer device 100 in the second state includes a magnetically conductive adhesive 140C. The two magnetically conductive adhesives 140C disposed on both sides of the primary coil 120 have the same shape, both being closed ring structures with one end being a straight side.

[0018] Compared to the first state, the transformer device 100 in the second state may further include a coil frame 150A, wherein the coil frame 150A is surrounded by the first magnetic core 111 and the second magnetic core 112 of the magnetic core assembly 110, and the coil frame 150A includes connected winding shaft portions 151 and receiving portions 152, wherein the number of winding shaft portions 151 is configured to correspond to the primary coil 120, and the number of receiving portions 152 is configured to correspond to the secondary coil 130.

[0019] In one embodiment, a single axial portion 151 can be wound with a primary coil 120, that is, the primary coil 120 can be disposed on the axial portion 151, and two receiving portions 152 are respectively connected to both ends of the axial portion 151 so that two secondary coils 130 can be disposed in the two receiving portions 152 respectively. Specifically, the receiving portion 152 is a dish-groove structure, and the secondary coil 130 formed by stacking multiple metal sheet-like parts 131 can be accommodated in this dish-groove structure.

[0020] In one embodiment, two magnetically conductive adhesive elements 140C are respectively attached to two secondary coils 130, and are housed together with the attached secondary coils 130 in the dish-like structure of the receiving portion 152. That is, when the magnetically conductive adhesive element 140C is attached to the secondary coil 130, the magnetically conductive adhesive element 140C is disposed in the receiving portion 152. However, in other embodiments, if only the aforementioned magnetically conductive adhesive element 140B is used, the magnetically conductive adhesive element 140B can be fixed to the primary coil 120. Since the magnetically conductive adhesive element 140B has a notch, the magnetically conductive adhesive element 140B can pass through the shaft portion 151 together with the primary coil 120 and be attached to the primary coil 120. In the design of the transformer assembly 100, which further includes a coil frame 150A, the primary coil 120 and the secondary coil 130 are separated by the coil frame 150A and do not contact each other, so that the magnetic adhesive can be set at different positions on the coil frame 150A depending on whether it is attached to the primary coil 120 (when only the magnetic adhesive 140B is used) or the secondary coil 130 (when the magnetic adhesives 140A, 140B, and 140C are used).

[0021] In one embodiment, as shown in FIG2B, the transformer device 100 may include a plurality of pins 160, and the coil frame 150A further includes two leads 153 arranged symmetrically to each other, wherein the two leads 153 have a plurality of pin slots 153G so that the pins 160 can be respectively disposed in the plurality of pin slots 153G of the leads 153, and the primary coil 120 can selectively connect to two of the pins 160 through leads (not shown in the figure) according to actual usage requirements.

[0022] In one embodiment, the lead-out portion 153 is a horizontally extending (parallel to the XY plane in FIG. 2B) plate-like structure, such that the pin slots 153G are spaced apart along a direction parallel to the axial direction of the axial portion 151 of the coil frame 150A (i.e., parallel to the Y-axis in FIG. 2B). Furthermore, the transformer device 100 may also include a circuit board 170, and is connected to the circuit board 170 via the secondary coil 130. The circuit board 170 is, for example, a printed circuit board (PCB).

[0023] Please refer to Figures 3A and 3B, which illustrate exploded and assembled schematic diagrams of the transformer device 100 in the third state of the disclosed embodiment. The transformer device 100 in the third state includes a magnetic core assembly 110, a primary coil 120, a secondary coil 130, and magnetically conductive adhesive components 140A, 140B, and 140C, and may adopt similar or identical implementation details as described above, which will not be repeated here. The following focuses on describing the distinguishing features of this state.

[0024] Similar to the second state, the transformer device 100 in the third state may further include a coil frame 150B, and the coil frame 150B has the same purpose as the coil frame 150A. Both are provided for the primary coil 120 to be wound through a single winding shaft portion 151, and two secondary coils 130 are respectively placed in the two receiving portions 152 connected to both ends of the winding shaft portion 15. Then, they are surrounded by the first magnetic core member 111 and the second magnetic core member 112 of the magnetic core assembly 110.

[0025] In one embodiment, the magnetically conductive adhesive members 140A and 140B are respectively attached to their respective adjacent secondary coils 130, and are housed together with the attached secondary coils 130 in the dish-like structure of the receiving portions 152 on both sides.

[0026] The main difference compared to the second embodiment lies in the structure of the lead-out portion 153 of the coil frame 150B. Specifically, the lead-out portion 153 of the coil frame 150B is a plate-like structure extending vertically (parallel to the XZ plane in FIG. 3B), such that the lead slots 153G are spaced apart along a direction perpendicular to the axis of the coil frame 150B's axial portion 151 (i.e., parallel to the Z-axis in FIG. 3B), thereby reducing the finished volume of the transformer device 100. Similarly, as shown in FIG. 3B, the transformer device 100 in the third embodiment may also include a circuit board 170, and is connected to the circuit board 170 via the secondary coil 130.

[0027] Please refer to Figures 4A and 4B, which illustrate exploded and assembled schematic diagrams of the transformer device 100 in the fourth aspect of the disclosed embodiment. The following description focuses on the distinguishing features of this aspect. The transformer device 100 in the fourth aspect includes a magnetic core assembly 110, a primary coil 120, a secondary coil 130, and a magnetically conductive adhesive component 140A (magnetically conductive adhesive components 140B and 140C may also be used, which is not limited here), and can employ similar or identical implementation details as described above, which will not be repeated here. The following description focuses on the distinguishing features of this aspect.

[0028] In this configuration, the number of primary coils 120 and secondary coils 130 is multiple and they are arranged alternately. Multiple primary coils 120 and multiple secondary coils 130 are arranged alternately and in contact with each other. A single primary coil 120 and a single secondary coil 130 can be considered as constituting a coil group, that is, as shown in Figures 4A and 4B, there are four coil groups. The primary coil 120 can be connected to other devices or circuits via flying wires, and the secondary coil 130 can also be connected to a circuit board (not shown in the figures), but this is not a limitation; the number of coils can be increased or decreased according to practical needs.

[0029] In one embodiment, the coil groups consisting of primary coil 120 and secondary coil 130 are arranged in series in the magnetic core group 110, that is, the coil groups are passed through and clamped by the first magnetic core member 111 and the second magnetic core member 112 to fix them in the magnetic core group 110.

[0030] As shown in Figure 4A, a single magnetic adhesive element 140A is disposed in one of the coil groups, but is not limited thereto. In other embodiments, magnetic adhesive elements 140A may be provided in some coil groups (magnetic adhesive elements 140B and 140C may also be used); or each coil group may be provided with a magnetic adhesive element 140A; furthermore, magnetic adhesive elements 140A may also be provided between coil groups, that is, the number of magnetic adhesive elements 140A may be multiple, and a single magnetic adhesive element 140A may be provided between each pair of multiple coil groups.

[0031] Please refer to Figures 5A and 5B, which illustrate exploded and assembled schematic diagrams of the transformer device 100 in the fifth state of the disclosed embodiment, wherein the magnetic core assembly 110 is omitted in Figure 5A. The transformer device 100 in the fifth state includes the magnetic core assembly 110, the primary coil 120, the secondary coil 130, and the magnetically conductive adhesive component 140A, and may adopt similar or identical implementation details as described above, which will not be repeated here. The following focuses on describing the distinguishing features of this state.

[0032] Similar to the second and third states, the transformer device 100 in the fifth state may further include a coil frame 150C to separate the primary coil 120 and the secondary coil 130 so that they do not contact each other. In this state, the coil frame 150C serves a similar purpose to the coil frames 150A and 150B, providing a single winding portion 151 for the primary coil 120 to be wound around, but a single receiving portion 152 connected to one end of the winding portion 151 provides a single receiving portion 152 for the secondary coil 130 to be placed therein, and then surrounded by the first magnetic core 111 and the second magnetic core 112 of the magnetic core assembly 110. However, the receiving portion 152 of the coil frame 150C is not a dish-shaped structure, but a hollow barrel-shaped structure, through which the magnetically conductive adhesive 140A (or magnetically conductive adhesive 140B, 140C) and the secondary coil 130 can be passed for fixation. In this state, the magnetically conductive adhesive 140A can be attached to the adjacent secondary coil 130 and pass through the hollow barrel-shaped structure in the receiving portion 152 together with the attached secondary coil 130.

[0033] In one embodiment, the coil frame 150C has a lead-out portion 153 on one side of the receiving portion 152. The lead-out portion 153 of the coil frame 150C is a plate-shaped structure formed along a direction perpendicular to the axial direction of the coil frame 150A's axial portion 151 (parallel to the Y-axis in Figures 3A and 3B), such that the lead-out portion 153's pin slots 153G are arranged at intervals in the same direction (parallel to the X-axis in Figures 3A and 3B). Multiple pins 160 can be respectively provided in these pin slots 153G, and the primary coil 120 can selectively connect two of these pins 160 through leads (not shown) according to actual usage requirements. In this way, the structure of the transformer device 100 in the fifth state can provide a different pin direction than the second and third states.

[0034] Figure 6 is a schematic diagram of the magnetically conductive adhesive included in the transformer device 100 under all states of the embodiments disclosed herein.

[0035] As described above, the magnetically conductive adhesive components 140A, 140B, and 140C may each include a stacked insulating layer 141, a magnetically conductive layer 142, an adhesive layer 143, and a release layer 144. The insulating layer 141 is, for example, a polyethylene terephthalate (PET) film. The magnetically conductive layer 142 is, for example, an iron-based alloy with a nanocrystalline structure. The adhesive layer 143 is, for example, PET tape. The release layer 144 is, for example, a PET single-sided release film. The release layer 144 is removed during the assembly of the transformer assembly 100, allowing the magnetically conductive adhesive components 140A, 140B, and 140C to be attached to the primary coil 120 or the secondary coil 130 through the adhesive layer 143. In other words, the magnetically conductive adhesive components 140A, 140B, and 140C are a composite laminated material. In one embodiment, the stack thickness of the insulating layer 141, the magnetic conductive layer 142, and the adhesive layer 143 may be less than 1 mm.

[0036] Furthermore, the insulating layer 141, the magnetic conductive layer 142, and the adhesive layer 143 are all elastic and flexible, so that the magnetic conductive adhesive components 140A, 140B, and 140C are flexible structures to adapt to the installation environment of the primary coil 120 or the secondary coil 130 to which they are attached. In another embodiment, provided that the overall thickness of the magnetic conductive adhesive components 140A, 140B, and 140C is less than 1 mm, the magnetic conductive layer 142 is not limited to a single layer, that is, the number of magnetic conductive layers 142 can be multiple layers, so that multiple magnetic conductive layers 142 are arranged to stack and adhere to each other. Therefore, when the transformer device 100 is operating, the magnetic conductive adhesive components 140A, 140B, and 140C generate leakage inductance through the magnetic interference effect of their magnetic conductive layers 142.

[0037] As described above, this disclosure proposes a novel transformer device, which increases the leakage inductance of the transformer device itself by placing a magnetically conductive adhesive between the primary coil and the secondary coil, thereby eliminating the need to increase the distance between the primary coil and the secondary coil, and thus eliminating the need to increase the size of the transformer device, thereby reducing the size of the transformer.

[0038] In summary, although this disclosure has been presented above with reference to embodiments, it is not intended to limit this disclosure. Those skilled in the art to which this disclosure pertains can make various modifications and refinements without departing from the spirit and scope of this disclosure. Therefore, the scope of protection of this disclosure shall be determined by the appended claims. [Simplified Explanation of the Diagram]

[0007] Figure 1 shows an exploded view of the transformer device in the first state of the present disclosure embodiment. Figure 2A shows an exploded view of the transformer device in the second state of the present disclosure embodiment. Figure 2B shows an assembly diagram of the transformer device in the second state of the present disclosure embodiment. Figure 3A shows an exploded view of the transformer device in the third state of the present disclosure embodiment. Figure 3B shows an assembly diagram of the transformer device in the third state of the present disclosure embodiment. Figure 4A shows an exploded view of the transformer device in the fourth state of the present disclosure embodiment. Figure 4B shows an assembly diagram of the transformer device in the fourth state of the present disclosure embodiment. Figure 5A shows an exploded view of the transformer device in the fifth state of the present disclosure embodiment. Figure 5B shows an assembly diagram of the transformer device in the fifth state of the present disclosure embodiment. Figure 6 shows a schematic diagram of the magnetically conductive adhesive component included in the transformer device of the present disclosure embodiment.

Claims

1. A transformer device, comprising: One magnetic core assembly; At least one primary coil is disposed in the magnetic core assembly; at least one secondary coil is disposed in the magnetic core assembly; and at least one magnetically conductive adhesive member comprising an insulating layer, at least one magnetically conductive layer and an adhesive layer stacked together, and disposed between the at least one primary coil and the at least one secondary coil, wherein the at least one magnetically conductive adhesive member is attached to the at least one primary coil or the at least one secondary coil through the adhesive layer.

2. The transformer assembly as described in claim 1, wherein, The at least one primary coil comprises a plurality of metal sheets, each having a through hole at its center for the magnetic core assembly to pass through.

3. The transformer assembly as described in claim 1, wherein, The at least one primary coil is a wire winding, and a through hole is formed inside the wire winding for the magnetic core assembly to pass through the through hole.

4. The transformer assembly as described in claim 1, wherein, The magnetic adhesive component is a ring-shaped structure with a hole in the center, and the magnetic core assembly is inserted through the hole.

5. The transformer assembly as described in claim 1, wherein, The magnetic core assembly includes a first magnetic core and a second magnetic core arranged symmetrically, and the first magnetic core and the second magnetic core each have a protruding post inside, the two protruding posts forming a shaft, so that the at least one primary coil, the at least one secondary coil and the magnetically conductive adhesive are sleeved on the shaft formed by the two protruding posts.

6. The transformer device as claimed in claim 1 further includes a coil frame comprising at least one winding portion and at least one receiving portion connected together, wherein the at least one primary coil is wound on the at least one winding portion and the at least one primary coil is disposed in the at least one receiving portion such that the at least one primary coil and the at least one primary coil are not in contact.

7. The transformer assembly as described in claim 6, wherein, When the at least one magnetically conductive adhesive is attached to the at least one primary coil, the at least one magnetically conductive adhesive is disposed on the at least one axial portion.

8. The transformer assembly as described in claim 6, wherein, When the at least one magnetically conductive adhesive is attached to the at least one primary coil, the at least one magnetically conductive adhesive is disposed in the at least one receiving portion.

9. The transformer assembly as described in claim 6, wherein, The transformer assembly includes a plurality of pins, and the coil frame further includes at least one lead-out portion having a plurality of pin slots, wherein the plurality of pins are respectively disposed on the plurality of pin slots of the lead-out portion.

10. The transformer assembly as described in claim 9, wherein, The plurality of pin slots are spaced apart along a direction parallel to the axial direction of the shaft portion.

11. The transformer assembly as described in claim 9, wherein, The plurality of pin slots are spaced apart along a direction perpendicular to the axis of the shaft portion.

12. The transformer assembly as described in claim 1, wherein, The number of the at least one primary coil and the at least one secondary coil is multiple, and a single primary coil and a single secondary coil constitute a coil group, such that the multiple coil groups are arranged in series in the magnetic core group, and the at least one magnetically conductive adhesive is disposed in at least one of the multiple coil groups.

13. The transformer assembly as described in claim 12, wherein, The number of the at least one magnetically conductive adhesive component is multiple, and each pair of the multiple coil groups is provided with a single magnetically conductive adhesive component.

14. The transformer assembly as described in claim 1, wherein, The stacked thickness of the insulating layer, the at least one magnetic conductive layer, and the adhesive layer is less than 1 mm.

15. The transformer assembly as described in claim 1, wherein, At least one of the magnetically conductive adhesive components is a flexible structure.

16. The transformer assembly as described in claim 1, wherein, The number of the at least one magnetically conductive layer is multiple, and the multiple magnetically conductive layers are stacked on top of each other.

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