Transformer-inductor combination device
By designing a combined transformer/inductor device, utilizing the central core leg, external core legs, inner and outer frames, and winding structure, the problems of large footprint and high cost of independent devices are solved, realizing a combined transformer/inductor device with low footprint and low cost.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- VISHAY DALE ELECTRONICS INC
- Filing Date
- 2020-06-08
- Publication Date
- 2026-04-17
AI Technical Summary
In the prior art, independent transformer and inductor devices occupy a large area and do not share manufacturing steps, resulting in high manufacturing costs and making it difficult to achieve a combined transformer/inductor device with low footprint and low cost.
A combined transformer/inductor device was designed, including core components with a central core leg and an outer core leg, inner and outer frames and winding structure, which are combined into a transformer and inductor device through specific winding and assembly methods.
This approach combines transformers and inductors, reducing footprint and manufacturing costs while maintaining good electrical characteristics and ease of manufacture.
Smart Images
Figure CN113994444B_ABST
Abstract
Description
[0001] Cross-reference to related applications
[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 62 / 873,468, filed July 12, 2019, and U.S. Non-Provisional Patent Application Serial No. 16 / 661,408, filed October 23, 2019, both of which are incorporated herein by reference. Technical Field
[0003] The disclosed concepts generally relate to electrical components, and more specifically to magnetic devices such as inductors and transformers. Background Technology
[0004] Resonant converters are used in a variety of applications, such as power conversion. For example, resonant converters are commonly used in automotive charging applications. They are also used in several other industries, including alternative energy, military, and industrial applications.
[0005] Resonant transducers typically include transformer windings that are electrically connected to a resonant circuit that includes an inductor. Some applications require larger resonant inductance.
[0006] In commercial applications, the transformer and inductor in a resonant circuit are separate units, which allows for easy selection of their electrical characteristics. However, separate units result in a larger footprint compared to combined units. Furthermore, separate units do not share any components or manufacturing steps. Combined transformer / inductor units can offer a lower footprint and manufacturing cost. However, creating a combined transformer / inductor unit that maintains suitable electrical characteristics and is easy to manufacture is challenging.
[0007] There is room for improvement in combined transformer / inductor devices. Summary of the Invention
[0008] According to one aspect of the disclosed concept, a combined transformer / inductor device includes: a core having a central core leg and outer core legs spaced apart from the central core leg; an inner frame disposed around the central core leg; an outer frame disposed around the inner frame and the central core leg and having an upper portion, a lower portion and a central portion, the upper portion having a first elongated oval portion disposed around the outer core leg, the lower portion having a second elongated oval portion disposed around the outer core leg, and the central portion being disposed around the inner frame and the central core leg; a first winding wound around the inner frame; and a second winding wound around the outer frame, the second winding having a first portion wound around the first elongated oval portion, a second portion wound around the central portion and a third portion wound around the second elongated oval portion.
[0009] According to one aspect of the disclosed concept, the core includes: a central core leg; and an outer core leg spaced apart from the central core leg, wherein the outer core leg has an arcuate outer surface.
[0010] According to one aspect of the disclosed concept, the skeleton includes: an inner portion having a first opening formed therein; an upper portion having a first elongated oval portion extending from the inner portion and having an upper opening therein; and a lower portion having a second elongated oval portion extending from the inner portion and having a lower opening therein, wherein the upper portion extends to less than or equal to half the height of the skeleton, and the lower portion extends to less than or equal to half the height of the skeleton.
[0011] According to one aspect of the disclosed concept, a method of assembling a combined transformer / inductor device includes: winding an inner frame; winding an outer frame, wherein winding the outer frame includes: winding a first portion of the outer frame around an inner portion and a first elongated portion of the outer frame, and winding a central portion of the outer frame around the inner portion of the outer frame; sliding the inner frame into the outer frame; sliding the inner frame and the outer frame onto a central leg and an outer leg of a core; and connecting an upper portion and a lower portion of the core. Attached Figure Description
[0012] A full understanding of the disclosed concepts can be obtained from the following description of preferred embodiments when read in conjunction with the accompanying drawings, in which:
[0013] Figure 1 This is an exploded view of a combined inductor / transformer device according to an example embodiment of the disclosed concept;
[0014] Figure 2A This is a top view of a combined inductor / transformer device according to an example embodiment of the disclosed concept;
[0015] Figure 2B yes Figure 2A A side sectional view of an inductor-transformer assembly;
[0016] Figure 3A It is a perspective view of an upper core or lower core according to an example embodiment of the disclosed concept;
[0017] Figure 3B yes Figure 3A A bottom view of the upper or lower core component;
[0018] Figure 3C yes Figure 3A A side view of the upper or lower core component;
[0019] Figure 4AIt is a perspective view of the internal skeleton according to an example embodiment of the disclosed concept;
[0020] Figure 4B yes Figure 4A Top view of the internal skeleton;
[0021] Figure 4C yes Figure 4A Side view of the internal skeleton;
[0022] Figure 4D yes Figure 4A Another side view of the internal skeleton;
[0023] Figure 5A This is a perspective view of the exoskeleton of an example embodiment of the disclosed concept;
[0024] Figure 5B yes Figure 5A Top view of the exoskeleton;
[0025] Figure 5C yes Figure 5A Side view of the exoskeleton;
[0026] Figure 5D yes Figure 5A Rear view of the exoskeleton;
[0027] Figure 6 This is a cross-sectional view of an inner skeleton nested within an outer skeleton, according to an example embodiment of the disclosed concept;
[0028] Figure 7 This is a flowchart of a method for assembling a combined transformer / inductor device according to an example embodiment of the disclosed concept;
[0029] Figure 8A It is a perspective view of an upper core or lower core according to an example embodiment of the disclosed concept;
[0030] Figure 8B yes Figure 8A A top view of the upper or lower core component;
[0031] Figure 9A It is a perspective view of the internal skeleton according to an example embodiment of the disclosed concept;
[0032] Figure 9B yes Figure 9A Top view of the internal skeleton;
[0033] Figure 10A It is a perspective view of the exoskeleton according to an example embodiment of the disclosed concept; and
[0034] Figure 10B yes Figure 10ATop view of the exoskeleton. Detailed Implementation
[0035] The directional terms used herein, such as, for example, left, right, front, back, top, bottom, and their derivatives, refer to the orientation of the elements shown in the accompanying drawings, and, unless expressly stated herein, do not limit the scope of the claims.
[0036] The term “number” as used in this article should refer to one or more (i.e., multiple) integers.
[0037] Figure 1 This is an exploded assembly diagram of a combined transformer / inductor device 100 according to an exemplary embodiment of the disclosed concept. Figure 2A This is a top view of the assembled combined transformer / inductor unit 100, and Figure 2B This is a cross-sectional view of the assembled combined transformer / inductor device 100.
[0038] The combined transformer / inductor assembly 100 includes cores 10 and 11, an inner frame 20, and an outer frame 30. The inner frame 20 is wound with a first winding 40, while the outer frame 30 is wound with a second winding 50. The first winding 40 forms one winding of the transformer, while the second winding 50 forms both a second winding of the transformer and a winding of the inductor. Thus, the combined transformer / inductor assembly 100 includes both a transformer and an inductor.
[0039] Cores 10 and 11 are formed by an upper core 10 and a lower core 11. The upper core 10 and lower core 11 may have similar shapes. However, it should be understood that the upper core 10 and lower core 11 may have different shapes without departing from the scope of the disclosed concepts. In some example embodiments, cores 10 and 11 may be based on PQ cores. However, cores 10 and 11 may be based on other types of cores without departing from the scope of the disclosed concepts. In some example embodiments, cores 10 and 11 may be made of ferrite, but other suitable materials may be used without departing from the scope of the disclosed concepts.
[0040] Figure 3A This is a 3D view of the upper core component 10. Figure 3B This is a bottom view of the upper core component 10, and Figure 3C This is a side view of the upper core member 10. As described above, the lower core member 11 may have the same or similar shape as the upper core member 10, therefore, Figures 3A-3CThe illustration can alternatively represent the lower core 11. The upper core 10 includes a central core leg 12 and an outer core leg 13. The central core leg 12 and the outer core leg 13 are spaced apart from each other. The central core leg 12 has a cylindrical shape (but may have other shapes without departing from the scope of the disclosed concept), and the outer core leg 13 has an arcuate outer surface (e.g., but not limited to, a crescent or half-moon shape, such as...). Figure 3A (As shown in the non-limiting example embodiments). It will be understood that the outer core leg 13 with an arcuate outer surface is merely one example of the outer core leg 13. The outer core leg 13 may have other shapes, such as those without an arcuate outer surface, without departing from the scope of the disclosed concepts. The central core leg 12 extends to align with the corresponding central core leg 12 of the lower core member 11. In some example embodiments, the outer core leg 13 is shorter than the central core leg 12. In some example embodiments, when the core members 10, 11 are assembled, there may be a gap between the outer core leg 13 of the upper core member 10 and the outer core leg 13 of the lower core member 11. For example, Figure 2B An air gap between the outer core legs 13 is shown. However, it should be understood that in the exemplary embodiments of the disclosed concept, an air gap may exist between the outer core legs 13, an air gap may exist between the central core legs 12, both may have air gaps, or neither may have air gaps, without departing from the scope of the disclosed concept.
[0041] The cylindrical shape of the central core leg 12 reduces the average length of the bend. The outer core leg 13 is positioned away from the central core leg 12 such that a portion of the second winding 50 extends around the outer core leg 13 in an elongated oval configuration, eliminating the need for external abrupt turns in the wire used in the second winding 50, thus allowing the wire to remain smooth.
[0042] The inner frame 20 is configured to surround the central core leg 12. The outer frame 30 is configured to extend not only around the central core leg 12, but also around the outer core leg 13, for example... Figure 2B As shown. The inner frame 20 has a smaller diameter than the outer frame 30, so that the inner frame 20 is nested inside the outer frame 30 when the combined transformer / inductor device 100 is assembled.
[0043] Figure 4A This is a perspective view of the inner skeleton 20 according to an example embodiment of the disclosed concept. Figure 4B This is a top view of the internal skeleton 20. Figure 4C It is a side view of the internal skeleton 20, and Figure 4DThis is another side view of the inner frame 20. In some example embodiments, the inner frame 20 may be made of a plastic material that insulates the first winding 40 from the cores 10, 11 and eliminates the need for sheathed wire. The inner frame 20 has a generally cylindrical shape with a central hollow opening 21 (but may have other shapes without departing from the scope of the disclosed concept). The diameter of the central hollow opening 21 is slightly larger than the diameter of the central core leg 12, allowing the inner frame 20 to slide onto the central core leg 12.
[0044] The inner frame 20 includes flanges 25 located at each end thereof. The flanges 25 insulate the first winding 40 from the cores 10, 11. Recesses 24 are formed in the flanges 25, allowing wires used in the first winding 40 to be led out. For example, the wires can pass through one of the recesses 24 and subsequently through corresponding recesses 15 formed in the cores 10, 11, where they can then be connected to external circuitry.
[0045] In some example embodiments, the inner frame 20 also includes a ridge 22 formed in the central portion of the inner frame 20. The ridge 22 separates the first winding 40 from the central portion of the central core leg 12. In some example embodiments, the central core leg 12 has an air gap and the ridge 22 can be used to isolate the first winding 40 from the air gap, so that eddy currents from the edge flux can be minimized. The ridge may extend only around a portion of the circumference of the inner frame 20, or in some example embodiments, it may extend around the entire circumference of the inner frame 20. For example, the ridge 22 may not extend in the region of the notch 24, thus allowing the wire path of the first winding 40 to be led out through the notch 24. However, it should be understood that the ridge 22 may be omitted without departing from the scope of the disclosed concept. For example, in some example embodiments where the central core leg 12 does not have an air gap, the ridge 22 may be omitted.
[0046] The flange 25 of the inner frame 20 may also include a locking recess 23. The locking recess 23 may correspond to the post 60 of the outer frame 30 (e.g., Figure 6(As shown). For example, locking notches 23 can be fitted into the posts 60 of the outer frame 30 to lock the inner frame 20 in place so that it does not rotate relative to the outer frame 30, thereby eliminating the need for glue or other adhesives. However, it should be understood that glue or other adhesives may still be used without departing from the scope of the disclosed concept. In some example embodiments, notches 24 are elongated in a direction toward the center of the inner frame 20, while locking notches 23 are elongated in a direction along the circumference of the flange 25. However, it should be understood that the shapes of notches 24 and locking notches 23 may be modified without departing from the scope of the disclosed concept. Locking notches 23 are concave features, meaning that they receive corresponding convex features, such as posts 60. However, locking notches 23 may be replaced by convex features, such as posts, and posts 60 may be replaced by concave features, such as notches, without departing from the scope of the disclosed concept.
[0047] Figure 5A This is a perspective view of the exoskeleton 30 according to an example embodiment of the disclosed concept. Figure 5B This is a top view of the exoskeleton 30. Figure 5C It is a side view of the exoskeleton 30, and Figure 5D This is a rear view of the outer frame 30. Like the inner frame 20, the outer frame 30 can be constructed of a plastic material that insulates the second winding 50 from the cores 10, 11, and the first winding 40. The outer frame 30 has a three-part shape comprising an upper portion, a lower portion, and a central portion. The outer frame 30 includes a cylindrical central hollow opening 31 (but may have other shapes without departing from the scope of the disclosed concept), which is common to the upper, lower, and central portions of the outer frame 30. The diameter of the central hollow opening 31 is slightly larger than the diameter of the flange 25 of the inner frame 20, allowing the inner frame 20 to be nested within the outer frame 30. The outer frame 30 also includes flanges 36 formed at its ends, which insulate the second winding 50 from the cores 10, 11, and the winding 40. Although sheathed wire can be used for windings 40 or 50, the outer frame 30 between the inner and outer windings 50 eliminates the need for voltage insulation using sheathed wire.
[0048] The upper portion of the exoskeleton 30 has an elongated oval shape. The upper portion includes an elongated oval portion 32 corresponding to the shape of the outer core leg 13. The elongated oval portion 32 extends away from the central hollow opening 31 of the exoskeleton 30. An outer hollow opening 34 is formed in the elongated oval portion 32. The shape of the outer hollow opening 34 corresponds to the shape of the outer core leg 13. In some example embodiments, both the outer core leg 13 and the outer hollow opening 34 have a crescent shape. The outer hollow opening 34 is slightly larger than the outer core leg 13, allowing it to slide on the outer core leg 13. The elongated oval portion 32 is defined at its upper and lower ends by flanges 36 and 37, which insulate the second winding 50 from the core members 10 and 11 and separate the second winding 50 from the air gap in the outer core leg 13, thereby minimizing eddy currents from the edge flux. The height of the elongated oval portion 32 is less than or equal to the height of the upper portion of the outer core leg 13, for example... Figure 2B As shown, this restricts the extension of the second winding 50 across the air gap in the outer core leg 13.
[0049] The lower portion of the exoskeleton 30 is generally similar to the upper portion of the exoskeleton 30. For example, the lower portion of the exoskeleton 30 includes an elongated oval portion 33 and an external hollow opening 35, the shapes of which are generally similar to the elongated oval portion 32 and the external hollow opening 34 in the upper portion of the exoskeleton 30.
[0050] The central portion of the exoskeleton 30, located between the upper and lower portions, does not include an elongated oval portion. Instead, the central portion comprises only a cylindrical portion of the exoskeleton 30, which includes a central hollow opening 31.
[0051] The second winding 50 can be constructed from a single continuous wire element. For example, the second winding 50 can be formed by winding the wire element around both the cylindrical and oblong portions 32 of the upper portion of the outer frame 30 a certain number of turns. The second winding 50 continues to be formed by winding the wire element around only the cylindrical portion of the outer frame 30 in the central portion a certain number of turns. Then, the second winding 50 continues to wind the wire element around both the cylindrical and oblong portions 33 of the lower portion of the outer frame 30 a certain number of turns to complete the required number of turns for both the transformer winding and the inductor winding. However, it should be understood that the winding order can be reversed, starting from the lower portion of the outer frame 30 and ending with the upper portion of the outer frame 30, without departing from the scope of the disclosed concept. The second winding 50 forms one winding of the transformer and one winding of the inductor. For example, the windings around the upper and lower portions of the outer frame 30 form the windings of an inductor, while the windings around the upper, lower, and central portions of the outer frame 30 form one winding of a transformer. The first winding 40 around the inner frame 20 forms another winding of the transformer. Thus, the combined transformer / inductor device 100 provides the functions of both a transformer and an inductor through the first and second windings 40, 50. A larger resonant inductance is provided by winding around the outer core leg 13 in an elongated oval shape, which is useful in resonant converter applications. In some example embodiments, the second winding 50 may be wound around only one of the upper and lower portions of the outer frame 30 and around the central portion of the outer frame 30. In applications where a larger resonant inductance is not required, winding the second winding 50 around only one of the upper and lower portions of the outer frame 30 and around the central portion of the outer frame 30 can provide sufficient resonant inductance.
[0052] The outer frame 30 may also include one or more recesses 38. The one or more recesses 38 may be formed in the flange 36 and allow wire leads for forming the second winding 50 to be led out.
[0053] Figure 6 This is a sectional view of the inner skeleton 20 nested within the outer skeleton 30. (Example) Figure 6 As shown, the outer frame 30 may further include one or more protrusions 61 extending into the central hollow opening 31 of the outer frame 30. These protrusions may function as vertical movement stops to prevent the inner frame 20 from moving vertically when the inner frame 20 is nested within the outer frame 30. For example, when the inner frame 20 is inserted into the outer frame 30 from above, the inner frame 20 will slide into the outer frame 30 until the flange 25 of the inner frame 20 abuts against the one or more protrusions 61, thus preventing further vertical movement through the outer frame 30. This aligns the inner frame 20 vertically with the outer frame 30 and prevents the inner frame 20 from sliding out of the outer frame 30.
[0054] Figure 7 This is a flowchart of a method for assembling a combined transformer / inductor device according to an example embodiment of the disclosed concept. Figure 7 The method can be used to assemble, for example Figure 2A and 2B The combined transformer / inductor device 100 is shown. The method will be described with respect to exemplary embodiments disclosed herein, but it should be understood that the method can be applied to other variations of the combined transformer / inductor device not explicitly disclosed herein without departing from the scope of the disclosed concepts.
[0055] The method begins at 101, in which the inner skeleton 20 is wound. The method continues at 102, in which the upper portion of the outer skeleton 30 is wound. The method continues at 104, in which the central portion of the outer skeleton 30 is wound, and continues to 106, in which the lower portion of the outer skeleton 30 is wound. As described herein, the winding around the upper and lower portions includes winding around the elongated portions 32 and 33 and around the cylindrical portions, respectively, while the winding around the central portion includes only winding around the cylindrical portions. It should also be understood that steps 102-106 can be performed in any order and / or one or more of these steps can be performed concurrently with one or more other steps without departing from the scope of the disclosed concept. It should also be understood that in some example embodiments, steps 102 or 106 may be omitted without departing from the scope of the disclosed concept. For example, in applications where a large resonant inductance is not required, sufficient inductance may be provided by winding only around one of the upper or lower portions of the outer skeleton 30. Furthermore, after the first winding 40 has been completed and before the second winding 50 is wound around the outer frame 30, the inner frame 20 can be nested inside the outer frame 30.
[0056] The method continues to step 108, in which the inner skeleton 20 slides into the outer skeleton 108. As described herein, locking features such as locking notches 23 and rod posts 60 can be used to align and lock the inner skeleton 20 relative to the outer skeleton 30 into place. Once the inner skeleton 20 has slid into the outer skeleton 30, the method continues to step 110, in which the connected inner skeleton 20 and outer skeleton 30 slide onto the central core leg 12 and outer core leg 13 of the core members 10, 11. Then, the method continues to step 112, in which the upper core member portion 10 and the lower core member portion 11 are connected to form the core members 10, 11, wherein the wound inner skeleton 20 and outer skeleton 30 are arranged around the central core leg 12 and outer core leg 13 within the core members 10, 11. This produces Figure 2A and 2B The combined transformer / inductor device 100 shown is illustrated.
[0057] It should be understood that the order of steps in this method may be changed without departing from the scope of the disclosed concepts. It should also be understood that additional steps may be incorporated into the method, such as, but not limited to, drawing out the wire, without departing from the scope of the disclosed concepts.
[0058] Although exemplary embodiments have been described with respect to a single winding on the inner frame 20 and a single winding wound around the outer frame 30, it should be understood that multiple windings may be wound around the inner frame 20 and / or the outer frame 30 without departing from the scope of the disclosed concepts. It should also be understood that the first winding 40 and the second winding 50, or other windings wound around the inner frame 20 and / or the outer frame 30, may be tapped at multiple locations without departing from the scope of the disclosed concepts.
[0059] Figure 8A This is a perspective view of the upper core 210 according to an example embodiment of the disclosed concept, and Figure 8B This is a top view of the upper core component 210. It should be understood that the upper core component 210 can also be a lower core component, without departing from the scope of the disclosed concept. It should also be understood that the upper core component 210 can be connected to a lower core component that is identical or similar to the upper core component 210, just as the upper core component 10 and the lower core component 11 are, for example... Figure 2B The connections shown are used to form a core component.
[0060] The upper core 210 includes a central core leg 212 and an outer core leg 213. The central core leg 212 and the outer core leg 213 are spaced apart from each other. The central core leg 212 has an elongated oval shape and the outer core leg 213 has an arcuate outer surface (e.g., but not limited to, such as...). Figure 8A (The non-limiting example embodiment shows a crescent shape). When the upper core 210 is connected to the lower core, an air gap may exist between the outer core leg 213 of the upper core 210 and the corresponding outer core leg 213 of the lower core. Similarly, an air gap may exist between the central core leg 212 of the upper core 210 and the corresponding central core leg of the lower core.
[0061] The upper core component 210 is somewhat similar to the above-mentioned components. Figures 3A-3C The upper core 10 is described. However, the central core leg 212 of the upper core 210 has an elongated oval shape instead of a cylindrical shape. Furthermore, in some example embodiments, the upper core 210 may have a smaller height than the upper core 10. The upper core 210 also includes inclined surfaces extending from the edges of the upper core 210 to the central core leg 212 and the outer core leg 213, respectively. The inclined surfaces form openings, thereby allowing wires to be easily led out from the windings surrounding the central core leg 212 and the outer core leg 213. Additionally, the upper core 210 includes a recess 216 formed along its outer edge (the recess 216 formed along the far outer edge is drawn from...). Figure 8A (View hidden in the middle). The recess 216 may be adapted to receive an attachment mechanism (e.g., but not limited to clips, straps, etc.) to connect the upper core 210 to the corresponding lower core.
[0062] It should be understood that the upper core 210 can be modified to include the features of the upper core 10 or the lower core 11 without departing from the scope of the disclosed concept, and similarly, the upper core 10 or the lower core 11 can be modified to include the features of the upper core 210 without departing from the scope of the disclosed concept.
[0063] Figure 9A This is a perspective view of the inner skeleton 220 according to an example embodiment of the disclosed concept, and Figure 9B This is a top view of the inner frame 220. In some example embodiments, the inner frame 220 may be made of a plastic material, which insulates the winding from the core and eliminates the need for sheathed wire. The inner frame 220 is generally oblong and has a central hollow opening 221. The diameter of the central hollow opening 221 is slightly larger than the diameter of the central core leg 212 of the upper core 210, allowing the inner frame 220 to slide onto the central core leg 212.
[0064] The inner frame 220 includes flanges 225 located at each of its ends; however, it should be understood that the flanges 225 may be omitted in some exemplary embodiments of the disclosed concept. The flanges 225 insulate the winding from the core. In some exemplary embodiments, the inner frame 220 also includes a ridge 222 formed in the central portion of the inner frame 220. The ridge 222 separates the winding from the central portion of the central core leg 212. In some exemplary embodiments, the central core leg 212 has an air gap, and the ridge 222 can be used to isolate the winding from the air gap, thereby minimizing eddy currents from the edge flux. The ridge may extend only around a portion of the circumference of the inner frame 220, thereby allowing the path of the winding wire to be led out. However, it should be understood that the ridge 222 may be omitted without departing from the scope of the disclosed concept. For example, in some exemplary embodiments where the central core leg 212 does not have an air gap, the ridge 222 may be omitted.
[0065] The internal skeleton 220 can be similar to the above regarding Figures 4A-4DThe inner skeleton 20 is described. However, the inner skeleton 220 includes an elongated oval central hollow opening 221, rather than a cylindrical central hollow opening 21. The elongated oval central hollow opening 221 may correspond to the shape of the central core leg 212 of the upper core 210, allowing the inner skeleton 220 to slide on the central core leg 212. It should be understood that the inner skeleton 220 may be modified to include features such as, but not limited to, notches 24, locking notches 23, or any other features of the inner skeleton 20, without departing from the scope of the disclosed concept. Similarly, it should be understood that the inner skeleton 20 may be modified to include features of the inner skeleton 220, without departing from the scope of the disclosed concept.
[0066] Figure 10A This is a perspective view of the exoskeleton 230 according to an example embodiment of the disclosed concept, and Figure 10B This is a top view of the outer frame 230. Like the inner frame 220, the outer frame 230 can be made of plastic material, which insulates the corresponding windings and cores of the outer frame from the windings corresponding to the inner frame 220. The outer frame 230 has a three-part shape comprising an upper portion, a lower portion, and a central portion. The outer frame 230 includes an elongated central hollow opening 231, which is shared by the upper, lower, and central portions. The diameter of the central hollow opening 231 is slightly larger than the diameter of the flange 225 of the inner frame 220, allowing the inner frame 220 to be nested within the outer frame 230. The outer frame 230 also includes flanges 236 formed at its ends, which insulate the corresponding windings and cores of the outer frame 230 from the windings corresponding to the inner frame 220. The outer frame 230 eliminates the need for voltage insulation using sheathed wire.
[0067] The upper portion of the exoskeleton 230 has an elongated oval shape. The upper portion includes an elongated section corresponding to the shape of the outer core leg 213. The elongated oval section extends away from the central hollow opening 231 of the exoskeleton 230. An outer hollow opening 234 is formed in the elongated oval section. The outer hollow opening 234 has a shape corresponding to the shape of the outer core leg 213. In some example embodiments, both the outer core leg 213 and the outer hollow opening 234 have a crescent shape. The outer hollow opening 234 is slightly larger than the outer core leg 213, allowing it to slide on the outer core leg 213. The elongated oval section is delimited at its upper and lower ends by flanges 236 and 237, which insulate the winding corresponding to the exoskeleton 230 from the core and separate the winding from the air gap in the outer core leg 213, thereby minimizing eddy currents from the edge flux. The height of the elongated portion is less than or equal to the height of the upper portion of the outer core leg 213, thereby limiting the winding extension across the air gap in the outer core leg 213.
[0068] The lower portion of the exoskeleton 230 is generally similar to the upper portion of the exoskeleton 230. For example, the lower portion of the exoskeleton 30 includes an elongated oval portion and an external hollow opening that are generally similar in shape to the elongated oval portion and the external hollow opening 234 in the upper portion of the exoskeleton 230.
[0069] The central portion of the exoskeleton 230, located between the upper and lower portions, does not include the elongated oval portion. Instead, the central portion only includes the elongated oval-shaped portion of the exoskeleton 230 that includes an elongated central hollow opening 231.
[0070] The exoskeleton 230 can be similar to the above regarding Figures 5A-5D The exoskeleton 30 is described. However, the exoskeleton 230 includes an elongated oval central hollow opening 231, rather than a cylindrical central hollow opening 31. The elongated oval central hollow opening 231 may correspond to the shape of the central core leg 212 of the upper core member 210, allowing the exoskeleton 230 to slide on the central core leg 212. It should be understood that the exoskeleton 230 can be modified to include features of the exoskeleton 30 without departing from the scope of the disclosed concept. Similarly, it should be understood that the exoskeleton 30 can be modified to include features of the exoskeleton 230 without departing from the scope of the disclosed concept.
[0071] The upper core 210 can be combined with the same or similar lower core to form a structure as described above. Figure 1 , 2A The cores 10 and 11 are similar to those described in 2B, formed by the upper core 10 and lower core 11. The inner frame 220 and outer frame 230 can be used with the upper core 210 and the corresponding lower core, as well as the corresponding first and second windings, to form a combined transformer / inductor device, similar to the cores 10 and 11, inner frame 20, outer frame 30, first winding 40, and second winding 50 described above. Figure 1 , 2A This is similar to the combined transformer / inductor device 100 described in 2B. For example, windings can be formed around an inner frame 220 and an outer frame 230, with the inner frame 220 nested within the outer frame 230. The inner frame 220 can slide onto the central core leg 212, and the outer frame 230 can slide onto the inner core leg 212 and the outer core leg 213, similar to... Figure 1 The assembly method of the combined transformer / inductor device 100.
[0072] Those skilled in the art will understand that the cylindrical and oblong shapes of the central core legs 12, 212 are non-limiting examples of shapes that can be used as central core legs. It should be understood that other shapes may be used without departing from the scope of the disclosed concepts. It should also be understood that the corresponding shapes of the openings in the inner and outer skeletons can be modified to correspond to any shape of central core leg without departing from the scope of the disclosed concepts.
[0073] Although specific embodiments of the disclosed concepts have been described in detail, those skilled in the art will understand that various modifications and alternatives to these details can be developed based on the general teachings of this disclosure. Therefore, the specific apparatus disclosed is intended to be illustrative and not limiting of the scope of the disclosed concepts, and the scope of the disclosed concepts shall be given full consideration to the appended claims and any and all their equivalents.
Claims
1. A combined transformer / inductor device (100), comprising: Core component (10, 11; 210), the core component having a central core leg (12; 212) and an outer core leg (13; 213) spaced apart from the central core leg (12; 212); An inner frame (20; 220) is arranged around the central core leg (12; 212); An exoskeleton (30; 230) is provided around the inner skeleton (20; 220) and the central core leg (12; 212) and has an upper portion, a lower portion, and a central portion. The upper portion has a first elongated oval portion (32) surrounding the outer core leg (13; 213), the lower portion has a second elongated oval portion (33) surrounding the outer core leg (13; 213), and the central portion is provided around the inner skeleton (20; 220) and the central core leg (12; 212). The first winding (40) is wound around the inner frame (20; 220); and The second winding (50) is wound around the outer frame (30; 230) and has a first portion wound around the first oblong portion (32), a second portion wound around the central portion and a third portion wound around the second oblong portion (33).
2. The combined transformer / inductor device (100) of claim 1, wherein, The upper portion of the exoskeleton (30; 230) includes a first flange (37; 237) disposed along a first lower edge of the upper portion, and the lower portion of the exoskeleton (30; 230) includes a second flange (37; 237) disposed along a first upper edge of the lower portion.
3. The combined transformer / inductor device (100) of claim 2, wherein, The upper portion of the exoskeleton includes a third flange (36; 236) disposed along the second upper edge of the upper portion, and the lower portion of the exoskeleton (30; 230) includes a fourth flange (36; 236) disposed along the second lower edge of the lower portion.
4. The combined transformer / inductor device (100) of claim 1, wherein, The central portion of the outer frame (30) includes one or more protrusions (61) configured to abut against the inner frame (20) to prevent the inner frame (20) from moving vertically in one direction beyond a predetermined point within the outer frame (30).
5. The combined transformer / inductor device (100) according to claim 1, wherein, The exoskeleton (30) includes at least one first locking feature (60) and the inner skeleton (20) includes at least one second locking feature (23), wherein the at least one first locking feature (60) is configured to interact with the at least one second locking feature (23) to prevent the inner skeleton (20) and the exoskeleton (30) from rotating relative to each other.
6. The combined transformer / inductor device (100) according to claim 5, wherein, The at least one first locking feature (60) includes one of a rod and a notch, and the at least one second locking feature (23) includes the other of a rod and a notch.
7. The combined transformer / inductor device (100) as described in claim 1, wherein, The central core leg (12) has a generally cylindrical shape.
8. The combined transformer / inductor device (100) according to claim 1, wherein, The central core leg (212) has a generally oblong shape.
9. The combined transformer / inductor device (100) according to claim 1, wherein, The outer core leg (13; 213) includes an arcuate outer surface.
10. The combined transformer / inductor device (100) according to claim 9, wherein, The outer core legs (13; 213) have a generally crescent shape.
11. The combined transformer / inductor device (100) according to claim 1, wherein, The core (10, 11) includes an upper core (10; 210) and a lower core (11; 210).
12. The combined transformer / inductor device (100) according to claim 11, wherein, The upper core (210) includes at least one first recess (216) formed along the upper edge of the upper core, and the lower core (210) includes at least one second recess (216) formed along the lower edge of the lower core, wherein the at least one first and second recesses (216) are configured to receive a strap or clip for fastening the upper core (210) and the lower core (210) together.
13. The combined transformer / inductor device (100) according to claim 1, wherein, The outer core leg (13; 213) and / or the central core leg (12; 212) include an air gap.
14. The combined transformer / inductor device (100) according to claim 1, wherein, The inner frame (20) includes at least one notch (24) configured to allow the first winding to be brought out.
15. The combined transformer / inductor device (100) according to claim 1, wherein, The inner skeleton (20; 220) includes at least one ridge (22; 222) formed around at least a portion of the circumference of the inner skeleton (220).
16. The combined transformer / inductor device (100) according to claim 1, wherein, The first winding (40) forms the first winding of the transformer, and the second winding (50) forms the second winding of the transformer and the winding of the inductor.
17. A method for assembling the combined transformer / inductor device according to claim 1, the method comprising: Wrapped inner skeleton (20; 220）； Wrapped exoskeleton (30; 230), wherein the winding exoskeleton includes: The first part of the exoskeleton (30; 230) is wrapped around the inner portion and the first elongated oval portion of the exoskeleton; and The inner portion of the outer frame (30; 230) is wrapped around the central portion of the outer frame (30; 230); The inner frame (20; 220) is slid into the outer frame (30; 230); The inner and outer skeletons are slid onto the central core leg (12; 212) and outer core leg (13; 213) of the core member (10, 11; 210); and The upper core (10; 210) and the lower core (11; 210) of the core are connected.
18. The method according to claim 17, wherein, The wrapped exoskeleton (30; 230) also includes: The second part of the outer frame (30; 230) is wrapped around the inner portion and the second oblong portion of the outer frame (30; 230). The central portion of the outer frame (30; 230) is located between the first and second portions of the outer frame (30; 230).
Citation Information
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