Power Converter

Abstract

The present disclosure provides a power converter, including a first coil component, a second coil component, a body and a core component. The second coil component is electrically independent of the first coil component. The body includes a first accommodation space, a second accommodation space and a third accommodation space. The first accommodation space is used to accommodate at least a portion of the first coil component. The second accommodation space is used to accommodate at least a portion of the second coil component. The core component corresponds to the first coil component and the second coil component. At least a portion of the core component is disposed in the third accommodation space of the body, and the first accommodation space is independent of the second accommodation space.

Description

Technical Field

[0001] The present disclosure relates to a power converter, and more particularly, to a power converter that is easy to assemble. Background Art

[0002] Power converters (such as transformers) are one of the indispensable components in electronic products. The main function of transformers is to convert the driving voltage in electronic circuits. For example, power transformers can reduce the mains voltage, and transformers can increase / decrease the working voltage in the external power supply (AC Adapter) module used in notebook computers. Therefore, the specifications of transformers are quite complicated and there are few fixed specifications. Most transformers are customized according to customer needs.

[0003] In order to avoid electromagnetic interference generated by the coil in the transformer, some transformers are provided with metal sheets, and the wires are connected to the metal sheets by welding or gluing. However, the welding or gluing method can generally only be performed manually, which is not conducive to automated operations, and the wires are easily detached or peeled off from the metal sheet due to collision or poor processing, resulting in the loss of the effect of preventing electromagnetic interference.

[0004] Therefore, how to design a power converter that can meet various needs of users is a topic worth exploring and solving today. Summary of the invention

[0005] In view of this, the present disclosure provides a power converter to solve the above-mentioned problem.

[0006] The present disclosure provides a power converter, including a first coil component, a second coil component, a body and a core component. The second coil component is electrically independent of the first coil component. The body includes a first accommodation space, a second accommodation space and a third accommodation space. The first accommodation space is used to accommodate at least a portion of the first coil component. The second accommodation space is used to accommodate at least a portion of the second coil component. The core component corresponds to the first coil component and the second coil component. At least a portion of the core component is disposed in the third accommodation space of the body, and the first accommodation space is independent of the second accommodation space.

[0007] According to some embodiments of the present disclosure, an area of ​​a cross section of a first coil unit of the first coil assembly is smaller than an area of ​​a cross section of a second coil unit of the second coil assembly.

[0008] According to some embodiments of the present disclosure, a cross-section of the second coil unit has a rectangular structure, and an extension direction of a long axis of the rectangular structure is neither perpendicular nor parallel to a winding axis of the second coil unit.

[0009] According to some embodiments of the present disclosure, the power converter further includes a first covering element connected to the body to form a second accommodating space.

[0010] According to some embodiments of the present disclosure, the main body has a first side wall, the first side wall has a first side wall surface, the first covering element has a second side wall, adjacent to the first side wall, the second side wall has a second side wall surface, the first side wall surface and the second side wall surface are parallel to each other, and the first side wall surface and the second side wall surface are neither parallel to nor perpendicular to the winding axis.

[0011] According to some embodiments of the present disclosure, the power converter also includes a protection element connected to the main body, and the main body is located between the core component and the protection element, wherein a gap is formed between the first covering element and the core component, and the protection element is inserted into the gap to connect with the main body.

[0012] According to some embodiments of the present disclosure, the first covering element includes at least two positioning members, and an input end and an output end of the first coil assembly are electrically connected to the two positioning members, respectively.

[0013] According to some embodiments of the present disclosure, the positioning member has an extension direction, and when viewed along the extension direction, the first coil component is partially exposed, and the second coil component is not exposed.

[0014] According to some embodiments of the present disclosure, the first covering element and the body form an opening, and when viewed along the extension direction, the second coil assembly is exposed through the opening.

[0015] According to some embodiments of the present disclosure, the power converter further includes a second coil assembly and a third coil unit, which is disposed in the second accommodating space, and when viewed along a direction perpendicular to the winding axis, the second coil unit partially overlaps the third coil unit.

[0016] According to some embodiments of the present disclosure, the distance between the outermost circle of the first coil component and the winding axis is different from the distance between the outermost circle of the second coil component and the winding axis.

[0017] According to some embodiments of the present disclosure, the body is made of bakelite.

[0018] According to some embodiments of the present disclosure, a thickness of an insulating layer of the first coil component is different from a thickness of an insulating layer of the second coil component.

[0019] The present disclosure provides a power converter, which forms a first accommodating space and a second accommodating space independently of each other by combining a body and a first covering element, so as to accommodate a first coil component and a second coil component respectively. Based on this structural design, the power converter of the present disclosure does not need to use insulating elements such as insulating tape to reduce interference between coil components, and has the advantages of convenient assembly, reduced process complexity, and increased process efficiency.

[0020] In addition, the input end and the output end of the first coil assembly can be automatically wound on the positioning piece by a machine, thereby further achieving the purpose of reducing labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present disclosure can be clearly understood through the detailed description below and in conjunction with the drawings. It is emphasized that, in accordance with standard practice in the industry, various features are not drawn to scale and are only used for illustrative purposes. In fact, in order to be able to clearly illustrate, the size of various features may be arbitrarily enlarged or reduced.

[0022] Figure 1 It is a three-dimensional schematic diagram of a power converter according to an embodiment of the present disclosure.

[0023] Figure 2 FIG. 4 is an exploded view of a power converter according to an embodiment of the present disclosure.

[0024] Figure 3 A power converter according to an embodiment of the present disclosure Figure 1 Schematic diagram of the cross section along the AA section line.

[0025] Figure 4 According to an embodiment of the present disclosure Figure 3 Enlarged view of the middle range P.

[0026] Figure 5 FIG. 4 is a schematic three-dimensional diagram of a power converter according to an embodiment of the present disclosure at another viewing angle.

[0027] Figure 6 FIG. 4 is a schematic rear view of a power converter according to an embodiment of the present disclosure.

[0028] Figure 7 FIG. 4 is a front view of a power converter according to an embodiment of the present disclosure.

[0029] Figure 8 It is a three-dimensional schematic diagram of a main body and a first covering element according to an embodiment of the present disclosure.

[0030] Fig. 9 FIG. 4 is a front view of a power converter according to another embodiment of the present disclosure.

[0031] Fig.10FIG. 4 is a partial structural diagram of a power converter according to another embodiment of the present disclosure.

[0032] Fig.11 FIG. 4 is a front schematic diagram of a power converter according to another embodiment of the present disclosure.

[0033] The reference numerals are as follows:

[0034] 100: Power Converter

[0035] 100A:Power Converter

[0036] 100B: Power Converter

[0037] 101: First coil assembly

[0038] 1010: first conductor

[0039] 1011: Input terminal

[0040] 1012: Output terminal

[0041] 102: Shell

[0042] 103: Second coil assembly

[0043] 1030: Second wire

[0044] 1031: First End

[0045] 1032: Second end

[0046] 103U2: Second coil unit

[0047] 103U3: The third coil unit

[0048] 104:Ontology

[0049] 1041: Hollow cylinder

[0050] 1043: first side wall

[0051] 1045: first side wall surface

[0052] 1047: Positioning structure

[0053] 106: First covering element

[0054] 1061: Second side wall

[0055] 1063: second side wall surface

[0056] 1067: Positioning structure

[0057] 108: Core assembly

[0058] 1081: Upper part

[0059] 1082: Lower part

[0060] 1083: protrusion

[0061] 1084: protrusion

[0062] 1085: cylindrical core

[0063] 110: First covering element

[0064] 1101: Positioning piece

[0065] 1102: Positioning piece

[0066] AS1: First storage space

[0067] AS2: Second storage space

[0068] AS3: The third storage space

[0069] AX: Winding axis

[0070] CA1: Section

[0071] CA2: cross section

[0072] GP: Gap

[0073] LX: Long axis

[0074] P: Range

[0075] PH: Open

[0076] X: X-axis

[0077] Y: Y axis

[0078] Z: Z axis DETAILED DESCRIPTION

[0079] In order to make the purpose, features and advantages of the present disclosure more obvious and easy to understand, the following embodiments are specifically cited and described in detail with the accompanying drawings. Among them, the configuration of each component in the embodiment is for illustrative purposes and is not intended to limit the present disclosure. In addition, some of the figure numbers in the embodiments are repeated to simplify the description and do not mean the correlation between different embodiments. The directional terms mentioned in the following embodiments, such as: up, down, left, right, front or back, etc., are only referenced to the directions of the attached drawings. Therefore, the directional terms used are used to illustrate and are not used to limit the present disclosure.

[0080] It is necessary to understand that the elements specifically described or illustrated may exist in various forms for those skilled in the art. In addition, when a layer is "on" another layer or substrate, it may mean "directly" on the other layer or substrate, or on the other layer or substrate, or between other layers or substrates.

[0081] In addition, relative terms such as "lower" or "bottom" and "upper" or "top" may be used in the embodiments to describe the relative relationship of one element to another element in the diagram. It is understood that if the device in the diagram is turned upside down, the element described on the "lower" side will become the element on the "upper" side.

[0082] Here, the terms "about" and "approximately" generally mean within 20%, preferably within 10%, and more preferably within 5% of a given value or range. The quantities given here are approximate quantities, which means that the meaning of "about" and "approximately" can still be implied in the absence of specific instructions.

[0083] Please refer to Figure 1 as well as Figure 2 , Figure 1 is a three-dimensional schematic diagram of a power converter 100 according to an embodiment of the present disclosure. Figure 2 FIG. 1 is an exploded view of a power converter 100 according to an embodiment of the present disclosure. The power converter 100 may be a transformer, including a housing 102 , a body 104 , a first coil assembly 101 , two second coil assemblies 103 , a first covering element 106 , a core assembly 108 and a first covering element 110 .

[0084] In this embodiment, the first coil assembly 101 is wound on the body 104, the body 104 has a hollow cylinder 1041, and the two second coil assemblies 103 are wound around a winding axis AX at the upper and lower ends of the hollow cylinder 1041. The first covering element 106 and the first covering element 110 are connected to the upper and lower sides of the body 104 respectively.

[0085] The core assembly 108 includes an upper component 1081 and a lower component 1082. A protrusion 1083 of the upper component 1081 passes through the first covering element 106 and is inserted into the hollow cylinder 1041. A protrusion 1084 of the lower component 1082 passes through the first covering element 110 and is inserted into the hollow cylinder 1041, and then forms a columnar core with the upper component 1081. The housing 102 is sleeved outside the core assembly 108 and the body 104 to ensure a safe standard distance between the first coil assembly 101, the second coil assembly 103 and external electronic components.

[0086] In this embodiment, the body 104 may be referred to as a coil frame (BOBBIN), which may be made of a plastic material, such as bakelite, but not limited thereto, so as to isolate the first coil component 101 and the second coil component 103 to avoid mutual interference.

[0087] It is worth noting that a first wire 1010 of the first coil component 101 has an insulating layer, and a second wire 1030 of the second coil component 103 also has an insulating layer, and the thickness of the insulating layer of the first wire 1010 is different from the thickness of the insulating layer of the second wire 1030. For example, the thickness of the insulating layer of the first wire 1010 is thicker to comply with the safety specification of the power converter 100.

[0088] It is worth noting that, in some embodiments, the distance between the outermost circle of the first wire 1010 of the first coil assembly 101 and the winding axis AX is different from the distance between the outermost circle of the second wire 1030 of the second coil assembly 103 and the winding axis AX.

[0089] Please refer to Figure 3 , Figure 3 The power converter 100 according to an embodiment of the present disclosure is Figure 1 Schematic diagram of the cross section along the AA section line. Figure 3 As shown, the protrusion 1083 and the protrusion 1084 are combined to form a columnar core 1085, corresponding to the first coil assembly 101 and the two second coil assemblies 103. The core assembly 108 and the body 104 form a first accommodation space AS1, which is used to accommodate a portion of the first coil assembly 101.

[0090] The first covering element 106 is connected to the body 104 to form a second accommodation space AS2, and the second accommodation space AS2 is used to accommodate a portion of the second coil assembly 103. It is worth noting that the first accommodation space AS1 is independent of the second accommodation space AS2. In addition, the hollow cylinder 1041 of the body 104 forms a third accommodation space AS3, and a portion of the core assembly 108 is disposed in the third accommodation space AS3.

[0091] like Figure 2 and Figure 3As shown, in this embodiment, the first coil component 101 can be a single coil unit (first coil unit), which is composed of a first wire 1010, and the first coil unit has an input end 1011 and an output end 1012. Similarly, the second coil component 103 can also be a single coil unit (second coil unit), which is composed of a second wire 1030, and the second coil unit has a first end 1031 and a second end 1032. The area of ​​a cross section CA1 of the first wire 1010 of the first coil unit is smaller than the area of ​​a cross section CA2 of the second wire 1030 of the second coil unit. Specifically, as Figure 3 As shown, the cross section CA2 has a rectangular structure, and the extension direction of a long axis LX of the rectangular structure is neither perpendicular nor parallel to the direction of the winding axis AX of the second conductive line 1030 .

[0092] Please refer to Figure 3 and Figure 4 , Figure 4 According to an embodiment of the present disclosure Figure 3 The enlarged view of the middle range P. As shown in the figure, the body 104 has a first side wall 1043, the first side wall 1043 has a first side wall surface 1045, the first covering element 106 has a second side wall 1061, adjacent to and abutting the first side wall 1043, and the second side wall 1061 has a second side wall surface 1063. The first side wall surface 1045 and the second side wall surface 1063 are parallel to each other, and the first side wall surface 1045 and the second side wall surface 1063 are neither parallel to nor perpendicular to the winding axis AX. Based on the design of the first side wall 1043 and the second side wall 1061, the assembly accuracy can be improved and the safe standard distance of the power converter 100 can be ensured.

[0093] Please refer to Figure 3 and Figure 5 , Figure 5 FIG. 1 is a schematic perspective view of a power converter 100 according to an embodiment of the present disclosure from another perspective. In this embodiment, the housing 102 may be referred to as a protection element, connected to the body 104, and as shown in FIG. Figure 3 As shown, the body 104 is located between the core assembly 108 and the housing 102 (protective element). Figure 5 As shown, a gap GP is formed between the first covering element 106 and the core assembly 108, and the housing 102 (protective element) is inserted into the gap GP to be connected to the body 104. The housing 102 is made of a non-conductive material, such as polyethylene terephthalate (PET), but is not limited thereto, and may also be made of bakelite, for example.

[0094] Please go back Figure 1 and Figure 2The first covering element 110 and the first covering element 106 may include a plurality of positioning elements, which may be pins extending along an extension direction, such as the -Y axis direction. The input end 1011 and the output end 1012 of the first coil assembly 101 are electrically connected to the positioning element 1101 and the positioning element 1102, respectively.

[0095] Please refer to Figure 6 , Figure 6 FIG. 1 is a schematic rear view of a power converter 100 according to an embodiment of the present disclosure. Figure 6 As shown, when viewed along the extension direction (-Y axis direction), the first coil assembly 101 is partially exposed, and the second coil assembly 103 is not exposed.

[0096] Please refer to Figure 7 , Figure 7 1 is a front view of a power converter 100 according to an embodiment of the present disclosure. The first cover element 106 and the body 104 form an opening PH, and when viewed along the Y axis (or the extending direction), the second coil assembly 103 is exposed through the opening PH.

[0097] When the power converter 100 is installed on a circuit board (not shown in the figure), a plurality of positioning members are inserted into the aforementioned circuit board to achieve positioning and make electrical connections, and the first end 1031 and the second end 1032 of the second coil component 103 can also be electrically connected to the electrical contacts on the circuit board, for example, by welding. In this embodiment, the first coil component 101 can be a primary side, and the input voltage can be, for example, 400 volts, and the two second coil components 103 can be connected in series through the circuit board as a secondary side, and the output voltage can be, for example, 12 volts. The power converter 100 disclosed in the present invention can be used for desktop computers or gaming computers, etc.

[0098] Please refer to Figure 8 , Figure 8 1 is a three-dimensional schematic diagram of a body 104 and a first covering element 106 according to an embodiment of the present disclosure. In this embodiment, the first covering element 106 has a positioning structure 1067, and the end of the hollow cylinder 1041 has a corresponding positioning structure 1047, and the positioning structure 1067 is a convex triangle, combined with the concave triangle positioning structure 1047. Based on the design of the above positioning structure, the assembly positioning accuracy of the first covering element 106 and the body 104 can be increased, and the first covering element 106 can also be prevented from rotating relative to the body 104.

[0099] Please refer to Fig. 9 and Fig.10 , Fig. 9is a front view of a power converter 100A according to another embodiment of the present disclosure, and Fig.10 FIG. 1 is a partial structural diagram of a power converter 100A according to another embodiment of the present disclosure. In this embodiment, the second coil assembly 103 includes two coil units (a second coil unit 103U2 and a third coil unit 103U3), both of which can be disposed in the second accommodation space AS2. Fig.10 As shown, when viewed along a direction (Y axis) perpendicular to the winding axis AX, the second coil unit 103U2 partially overlaps the third coil unit 103U3.

[0100] Please refer to Fig.11 , Fig.11 1 is a schematic diagram of a front view of a power converter 100B according to another embodiment of the present disclosure. In this embodiment, the power converter 100B can be composed of one or more bodies 104, a first covering element 106 and a first covering element 110, and can accommodate three first coil components 101 and four second coil components 103. Among them, the three first coil components 101 can be connected in series, and the four second coil components 103 can be connected in parallel through the aforementioned circuit board, thereby achieving the purpose of increasing the conductive efficiency of the power converter 100B, reducing the temperature and reducing the leakage current.

[0101] The present disclosure provides a power converter, wherein a first accommodating space AS1 and a second accommodating space AS2 are formed independently of each other by combining a body 104 with first covering elements 106 and 110, so as to respectively accommodate a first coil assembly 101 and a second coil assembly 103. Based on this structural design, the power converter of the present disclosure does not need to use insulating elements such as insulating tape to reduce interference between coil assemblies, and has the advantages of convenient assembly, reduced process complexity, and increased process efficiency.

[0102] In addition, the input end 1011 and the output end 1012 of the first coil assembly 101 can be automatically wound on the positioning members 1101 and 1102 by a machine, thereby further achieving the purpose of reducing labor costs.

[0103] Although the embodiments and advantages of the present disclosure have been disclosed as above, it should be understood that those skilled in the art may make changes, substitutions and modifications without departing from the spirit and scope of the present disclosure. In addition, the scope of protection of the present disclosure is not limited to the processes, machines, manufactures, material compositions, devices, methods and steps in the specific embodiments described in the specification. Any technician in the relevant technical field can understand the current or future developed processes, machines, manufactures, material compositions, devices, methods and steps from the content of the present disclosure, as long as they can implement substantially the same functions or obtain substantially the same results in the embodiments described herein, they can be used according to the present disclosure. Therefore, the scope of protection of the present disclosure includes the above-mentioned processes, machines, manufactures, material compositions, devices, methods and steps. In addition, each claim constitutes an individual embodiment, and the scope of protection of the present disclosure also includes the combination of each claim and embodiment.

Claims

1. A power converter, comprising: a first coil assembly; a second coil assembly, electrically independent of the first coil assembly; A body, comprising: A first accommodating space for accommodating at least a portion of the first coil assembly; a second accommodating space for accommodating at least a portion of the second coil assembly; and a third storage space; and An iron core component corresponding to the first coil component and the second coil component; wherein at least a portion of the core assembly is disposed in the third accommodation space of the body, and the first accommodation space is independent of the second accommodation space; The power converter further comprises a first covering element connected to the body to form the second accommodation space; The first covering element comprises at least two positioning members, and the positioning members have an extension direction; The second coil component is sleeved outside a hollow cylinder of the main body, and when observed along the extending direction, the first coil component is partially exposed, and the second coil component is not exposed. 2 . The power converter as claimed in claim 1 , wherein a cross-sectional area of ​​a first coil unit of the first coil assembly is smaller than a cross-sectional area of ​​a second coil unit of the second coil assembly. 3 . The power converter as claimed in claim 2 , wherein a cross section of the second coil unit has a rectangular structure, and an extension direction of a long axis of the rectangular structure is neither perpendicular nor parallel to a winding axis of the second coil unit.

4. A power converter as described in claim 3, wherein the body has a first side wall, the first side wall has a first side wall surface, the first covering element has a second side wall, adjacent to the first side wall, the second side wall has a second side wall surface, the first side wall surface and the second side wall surface are parallel to each other, and the first side wall surface and the second side wall surface are neither parallel to nor perpendicular to the winding axis.

5. A power converter as described in claim 3, wherein the power converter further includes a protection element connected to the main body, and the main body is located between the core component and the protection element, wherein a gap is formed between the first covering element and the core component, and the protection element is inserted into the gap to be connected to the main body. 6 . The power converter as claimed in claim 3 , wherein an input end and an output end of the first coil assembly are electrically connected to the two positioning members respectively. 7 . The power converter as claimed in claim 6 , wherein the first covering element and the body form an opening, and when viewed along the extending direction, the second coil assembly is exposed from the opening.

8. A power converter as described in claim 3, wherein the power converter further includes the second coil assembly and a third coil unit, which is arranged in the second accommodating space, and when observed along a direction perpendicular to the winding axis, the second coil unit partially overlaps the third coil unit. 9 . The power converter as claimed in claim 3 , wherein a distance between an outermost circle of the first coil component and a winding axis is different from a distance between an outermost circle of the second coil component and the winding axis.

10. The power converter as claimed in claim 1, wherein the body is made of bakelite. 11 . The power converter as claimed in claim 1 , wherein a thickness of an insulating layer of the first coil component is different from a thickness of an insulating layer of the second coil component.

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