Adjustable spacers for magnetic transformers and inductors

Abstract

A switch mode power supply includes at least one input and at least one output. The power supply also includes a power circuit coupled between the at least one input and the at least one output for converting an input voltage or current into an output voltage or current. The power circuit includes an electrical component having windings, an adjustable spacer positioned between the windings, and a core magnetically coupled to the windings. In addition, the adjustable spacer includes an adjustable thickness. Other example electrical components including adjustable spacers are also disclosed.

Description

Technical Field

[0001] The present disclosure relates to adjustable spacers, and in particular, to adjustable spacers for magnetic transformers and inductors. Background Art

[0002] This section provides background information related to the present disclosure which is not necessarily prior art.

[0003] Electrical components, such as transformers and inductors, are often used in switch-mode power supplies and often have windings formed from various types of wires and coils. The spacing between windings within an electrical component is often caused, for example, by one or more spacers that mechanically separate and / or support the windings. Summary of the invention

[0004] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0005] According to one aspect of the present disclosure, a switch mode power supply includes at least one input (1406) and at least one output (1408). The power supply also includes a power circuit coupled between the at least one input (1406) and the at least one output (1408) for converting an input voltage or current into an output voltage or current. The power circuit includes an electrical component having windings, an adjustable spacer positioned between the windings, and a core magnetically coupling the windings. In addition, the adjustable spacer includes an adjustable thickness.

[0006] According to another aspect of the present disclosure, a transformer includes one or more primary windings, one or more secondary windings, and a core that magnetically couples the one or more primary windings and the one or more secondary windings. The transformer also includes a spacer with an adjustable thickness positioned between the one or more primary windings and the one or more secondary windings.

[0007] According to another aspect of the present disclosure, an electrical component includes a magnetic core, at least one winding magnetically coupled to the magnetic core, and a spacer including a first section and a second section. The spacer also includes an adjustment mechanism coupled to the first section and the second section and configured to adjust a thickness of the spacer.

[0008] Other aspects and areas of applicability will become apparent from the description provided herein. It should be understood that the various aspects of the present disclosure can be implemented individually or in combination with one or more other aspects. It should also be understood that the description and specific embodiments herein are intended only for illustrative purposes and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0010] Figure 1 is an exploded view of an exemplary transformer.

[0011] Figure 2A-2B yes Figure 1 Top view of the transformer.

[0012] Figure 3 is included in Figure 1 A perspective view of an adjustable spacer in a transformer.

[0013] Figure 4 is a perspective view of another example adjustable spacer.

[0014] Figure 5 is a perspective view of another example adjustable spacer.

[0015] Fig. 6A is a perspective view of another example adjustable spacer.

[0016] Figure 6B yes Fig. 6A A top view of an adjustable spacer.

[0017] Figure 7 Yes Fig. 6A Exploded view of a transformer with adjustable spacers.

[0018] Figure 8A-B yes Figure 7 Perspective view of a transformer.

[0019] Fig. 9 yes Figure 7 Cross-sectional view of a transformer.

[0020] Fig. 10A is a perspective view of another example adjustable spacer.

[0021] Fig. 10B yes Fig. 10A A top view of an adjustable spacer.

[0022] Fig.11 Yes Fig. 10AExploded view of a transformer with adjustable spacers.

[0023] Figure 12A-12B yes Fig.11 Perspective view of a transformer.

[0024] Fig.13 yes Fig.11 Cross-sectional view of a transformer.

[0025] Fig.14 Yes Figure 1 Block diagram of a switched mode power supply (SMPS) with a transformer.

[0026] Corresponding reference numerals indicate corresponding parts or features throughout the several views of the drawings. DETAILED DESCRIPTION

[0027] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0028] Example embodiments are provided so that the present disclosure will be thorough and will fully convey the scope to those skilled in the art. Many specific details, such as embodiments of specific parts, devices and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and should not be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures and well-known techniques are not described in detail.

[0029] The terms used herein are only for the purpose of describing specific example embodiments and are not intended to be limiting. As used herein, the singular forms "a", "an", and "the" may also be intended to include plural forms unless the context clearly indicates otherwise. The terms "comprises", "comprising", "including", and "having" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, and / or groups thereof. The method steps, processes, and operations described herein are not to be interpreted as necessarily requiring them to be performed in the specific order discussed or illustrated, unless explicitly identified as an execution order. It should also be understood that additional steps or alternative steps may be adopted.

[0030] Although the term first, second, third etc. can be used herein to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or part from another region, layer or part. Terms such as "first", "second" and other numerical terms do not imply an order or sequence when used in this article, unless the context clearly indicates. Therefore, without departing from the teaching of the example embodiment, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part.

[0031] For ease of description, spatially relative terms such as "inside", "outside", "below", "below", "lower", "above", "upper", etc. may be used herein to describe the relationship of one element or feature to another element or feature as illustrated in the drawings. In addition to the orientation depicted in the drawings, spatially relative terms may be intended to include different orientations of the device in use or operation. For example, if the device in the drawings is flipped, the elements described as being "below" or "below" other elements or features will be oriented to be "above" the other elements or features. Therefore, the example term "below" may include both an orientation of "above" and an orientation of "below". The device may be oriented in other ways (rotated 90 degrees or in other orientations) and the spatially relative descriptions used herein may be interpreted accordingly.

[0032] A transformer according to an exemplary embodiment of the present disclosure is illustrated in Figure 1 1 and generally indicated by reference numeral 100. The transformer 100 includes a plurality of windings 102 (e.g., primary windings and secondary windings) and a core 104 that magnetically couples the windings 102. The transformer 100 also includes adjustable spacers 106 having an adjustable thickness for mechanically separating and supporting the windings 102.

[0033] The adjustable spacer 106 includes an adjustment mechanism 108 that permits the thickness of the adjustable spacer 106 to be adjusted within a range of thicknesses (e.g., as limited by the adjustment mechanism 108, etc.). Because the thickness of the adjustable spacer 106 can be adjusted, the adjustable spacer 106 is suitable for use with various electrical components (e.g., transformers, inductors, etc.) having the same core size, but different air gap sizes, configurations of windings (e.g., windings 102), numbers of windings (e.g., windings 102), material tolerances, etc. Specifically, one spacer (e.g., adjustable spacer 106) can be included in electrical components of a specific core size, where each component requires a spacer of a different thickness, rather than using multiple spacers or spacers of different thicknesses to achieve the desired thickness. As can be appreciated, a spacer with an adjustable thickness allows one part number to be used with a core size family (e.g., electrical components of a given core size) because the adjustable spacer 106 accommodates a range of thicknesses required for different electrical components. Furthermore, the adjustable spacer 106 may be sized and shaped for use with cores of different sizes and / or shapes.

[0034] In some embodiments, in addition to adjusting the thickness of the adjustable spacer 106, the adjustment mechanism 108 also permits the adjustable spacer 106 to be separated into a first section 110 and a second section 112 so that the first section 110 can be removably coupled to the second section 112. The sections 110 and 112 are also referred to herein as discs. Figure 1 As shown in the exploded view of FIG. 1 , the first disk 110 of the adjustable spacer 106 is detached from the second disk 112 of the adjustable spacer 106. In some embodiments, the first disk 110 and the second disk 112 can be moved relative to one another to adjust the thickness and cannot be separated.

[0035] like Figure 1 , the adjustable spacer 106 is positioned between the windings 102 within the transformer 100. In the illustrated embodiment, the adjustable spacer 106 is centrally positioned within the transformer 100. By doing so, the adjustable spacer 106 can position the windings 102 away from the air gap of the transformer 100. In this way, the fringing flux associated with the transformer 100 can be reduced (e.g., compared to a transformer including a spacer of a given thickness, etc.).

[0036] In an exemplary embodiment, the adjustment mechanism 108 is a screw-type adjustment mechanism and includes a pair of matching threads (i.e., threads 114 and threads 116). The threads 114 are included on the first disk 110 of the adjustable spacer 106, and the threads 116 are included on the second disk 112. As shown, the pair of threads 114, 116 are a matching pair of threads (e.g., threads 114 are internal threads and threads 116 are external threads) so that the disks 110, 112 of the adjustable spacer 106 can be tightened together and / or loosened. By tightening and / or loosening the adjustable spacer 106, the thickness of the adjustable spacer 106 can be changed, as described in more detail below. Although the exemplary embodiment illustrates a screw-type adjustment mechanism including threads, it is contemplated that other types of adjustment mechanisms (e.g., adjustment mechanisms including springs, steps, wedges, etc.) are used to change the thickness of the adjustable spacer 106.

[0037] The adjustable spacer 106 also includes a surface 118 on the first disk 110 and a surface 120 on the second disk 112. The surfaces 118 and 120 are generally planar and can interface with the winding 102. Specifically, when the adjustable spacer 106 is adjusted to a desired thickness, both the surfaces 118 and 120 can contact the winding 102. The contact of the surfaces 118, 120 with the winding 102 enables the adjustable spacer 106 to secure the winding 102 within the transformer 100 in a manner that ensures compactness of components within the transformer 100 and reduces fringing flux by positioning the winding away from an air gap of the transformer 100.

[0038] Figure 2A-2B The adjustable spacer 106 is illustrated when adjusted to a first thickness and a second thickness. Figure 2A , the adjustable spacer 106 is in a fully closed state. In the fully closed state, the adjustable spacer 106 is at its narrowest thickness, so that the threads 114 of the first disk 110 are fully engaged with the threads 116 of the second disk 112. In the illustrated embodiment, in the fully closed state, only the first disk 110 of the adjustable spacer 106 is in contact with the winding 102 (e.g., both disks 110 and 112 are not in contact with the winding 102). When only one of the disks of the adjustable spacer 106 (e.g., the first disk 110 or the second disk 112) is in contact with the winding 102, the winding 102 is allowed to move relative to the core 104.

[0039] In order to secure the windings 102 within the transformer 100 (and prevent damage to the windings 102 and / or core 104), the thickness of the adjustable spacer 106 may be altered or adjusted. Specifically, the adjustable spacer 106 may be adjusted to an increased thickness by rotating the second disk 112 relative to the disk 110, as indicated by arrow 122. When the second disk 112 is rotated, based on the configuration of the threads 114 and the threads 116, the second disk 112 moves outward along the central axis 124 of the transformer 100. After the rotation of the second disk 112, the threads 114 of the first disk 110 partially engage with the threads 116 of the second disk 112, placing the adjustable spacer 106 in a partially open state. In the partially open state, as shown in FIG. Figure 2B As shown in FIG. 1 , the two disks 110, 112 are in contact with the winding 102 via the surface 118 and the surface 120. When the two disks of the adjustable spacer 106 are engaged with the winding 102, the winding 102 is fixed in a manner to maintain the desired spacing and positioning of the components of the transformer 100 (e.g., compactness of the components, positioning the winding away from the air gap, etc.).

[0040] The adjustable spacer 106 also includes an opening 126 through the center of the adjustable spacer 106. The opening 126 permits the core 104 (e.g., a post of the core 104) to pass through the adjustable spacer 106. In the illustrated embodiment, the threads 114 and the threads 116 are generally positioned about the opening 126 (e.g., the threads 116 are positioned on an axis that defines the opening 126).

[0041] like Figure 3 As best shown in FIG. 1 , the adjustable spacer 106 optionally includes a plurality of notches 128 at the edges of the surfaces 118, 120. The notches 128 facilitate gripping of the adjustable spacer 106, for example, during rotation of the first disk 110 relative to the second disk 112 (e.g., when adjusting the thickness of the adjustable spacer 106). The notches 128 may be circular, square, etc. or any other shape that provides increased gripping and / or the ability to rotate the adjustable spacer 106.

[0042] Figure 4Another embodiment of an adjustable spacer 406 is illustrated that includes a spring-type adjustment mechanism having at least one spring 430. Similar to the adjustable spacer 106, the adjustable spacer 406 is suitable for use in an electrical component (e.g., a transformer, an inductor, etc.) including the transformer 100, for example, to separate the windings 102 included in the transformer 100 and / or provide space between the windings. The adjustable spacer 406 includes a first section or disk 410 and a second section or disk 412. In the illustrated embodiment, the adjustable spacer 406 includes two springs 430, one of which is positioned on the first disk 410 and the other of which is positioned on the second disk 412. Although each section is depicted as including one spring, each section of the adjustable spacer 406 may include a greater or lesser number of springs. The springs 430 are equally spaced around the adjustable spacer 406 to bias the adjustable spacer 406 to a uniform thickness (e.g., so that the disk 410 is parallel to the disk 412). As illustrated, the springs 430 are cantilever springs, but other types of springs (e.g., coil springs, etc.) may be suitable for inclusion in the spring-type adjustment mechanism of the adjustable spacer 406.

[0043] The adjustable spacer 406 also includes pins 432a, 432b and corresponding holes 434a, 434b, 434c, 434d for aligning the first disk 410 and the second disk 412. Specifically, the first disk 410 includes a pin 432a received by the hole 434a of the second disk 412 and a pin 432b received by the hole 434b of the second disk 412. The second disk 412 also includes a pin (not shown) received in the hole 434c of the first disk 410 and a pin (not shown) received in the hole 434d of the first disk 410. Although each section includes two pins, a greater or lesser number of pins (and corresponding holes) may be included in each section of the adjustable spacer 406. As shown in FIG. Figure 4 , each disk 410, 412 includes the same configuration of springs 430, pins 432a, 432b, and holes 434a, 434b, 434c, 434d, such that the first disk 410 of the adjustable spacer 406 is identical to the second disk 412 of the adjustable spacer 406. As can be appreciated, implementing the same configuration for the first disk 410 and the second disk 412 of the adjustable spacer 406 provides simplified manufacturing.

[0044] Due to the inclusion of the spring 430, the adjustable spacer 406 is biased to a maximum (e.g., widest) thickness. To reduce the thickness of the adjustable spacer 406, the adjustable spacer 406 is compressed as needed. Specifically, when included in a transformer (e.g., transformer 100), the winding 102 compresses the spring 430 of the adjustable spacer 406. The compression of the spring 430 of the adjustable spacer 406 is based at least in part on the available space within the winding area of ​​the transformer 100 (e.g., within the area defined by the core 104, etc.). In conjunction therewith, the inclusion of the spring 430 biases the winding 102 of the transformer 100 toward the core 104, so that the winding 102 is positioned away from the air gap (e.g., to reduce edge flux, etc.). In addition, the adjustable spacer 406 also includes a plurality of stops 436 to ensure that the pins 432a, 432b do not interfere with the windings 102 when the adjustable spacer 406 is compressed (e.g., the stops 436 prevent the pins 432a, 432b from fully passing through the discs 410, 412). As can be appreciated, in embodiments where the spring 430 is a cantilever spring, the adjustable spacer 406 is formed of a material (e.g., plastic, etc.) that permits the spring 430 to flex and compress as desired.

[0045] Figure 5Another embodiment of an adjustable spacer 506 is illustrated, which includes a step-type adjustment mechanism having at least one protruding step 538 and at least one recessed step 540a, 540b, 540c. Similar to the adjustable spacer 106, the adjustable spacer 506 is suitable for use in an electrical component (e.g., a transformer, an inductor, etc.) including a transformer 100, for example, to separate the windings 102 included in the transformer 100 and / or provide space between the windings. The adjustable spacer 506 includes a first section or disk 510 and a second section or disk 512. As shown in the illustrated embodiment, the first disk 510 includes a plurality of protruding steps 538 spaced equidistantly around the first disk 510. Specifically, the first disk 510 includes four protruding steps 538 located at the outer edge of the first disk 510, but a greater or lesser number of steps 538 may be included. The second disk 512 includes a plurality of corresponding recessed steps 540a, 540b, 540c of different depths, which are configured to receive the protruding steps 538 of the first disk 510. Specifically, the second disk 512 includes a group of recessed steps 540a of a first depth, a group of recessed steps 540b of a second depth, and a group of recessed steps 540c of a third depth. Each group of recessed steps 540a, 540b, 540c (e.g., the recessed steps 540a of the first depth) includes a number of steps corresponding to the number of the protruding steps 538 of the first disk 510, so that each of the protruding steps 538 of the first disk 510 can be received in only one group of recessed steps 540a, 540b, 540c of the second disk 512 at a given time (e.g., received in the recessed steps 540a of the first depth). Although only three sets of recessed steps 540a , 540b , 540c of different depths are depicted in the exemplary embodiment, a greater or lesser number of sets may be included to provide a different range of thicknesses for the adjustable spacer 506 .

[0046] In the illustrated embodiment, the protruding step 538 of the first disk 510 is aligned with the first set of recessed steps 540a. When the first disk 510 is coupled to the second disk 512 by inserting the protruding step 538 into the recessed step 540a, the thickness of the adjustable spacer 506 is at the narrowest thickness (e.g., based on the depth of the recessed step 540a). To adjust (e.g., increase) the thickness of the adjustable spacer 506, the first disk 510 can be rotated so that the protruding step 538 is aligned with and inserted into the recessed step 540b of the second disk 512, which has a smaller depth than the recessed step 540a. In this way, when the protruding step 538 is inserted into the recessed step 540b of the second disk 512, the thickness of the adjustable spacer 506 is increased because the depth of the recessed step 540b is shallower than the recessed step 540a. When the protruding step 538 of the first disk 510 is inserted into the recessed step 540c of the second disk 512, the adjustable spacer 506 is at the maximum thickness because these recessed steps have the smallest depth. Alternatively, instead of including a set of protruding steps of a given height and multiple sets of recessed steps of different depths, the adjustable spacer 506 can alternatively include multiple sets of protruding steps of different heights and a set of recessed steps of a given depth. Compared to the spiral-type adjustment mechanism 108 of the adjustable spacer 106 and the spring-type adjustment mechanism of the adjustable spacer 406, both of which provide a continuous transition along the thickness range of the adjustable spacer, the adjustment mechanism of the adjustable spacer 506 instead provides the adjustable spacer with a series of stepped or gradient thicknesses (e.g., three different thicknesses).

[0047] Figure 6A-6BAnother embodiment of an adjustable spacer 606 is illustrated that includes a wedge-type adjustment mechanism that includes a fastener, such as a cable tie 642. Similar to the adjustable spacers 106, 406, and 506, the adjustable spacer 606 is suitable for use in an electrical component (e.g., a transformer, an inductor, etc.) including the transformer 100, for example, to separate and / or provide space between the windings 102 included in the transformer 100. The adjustable spacer 606 includes a first section or disk 610 and a second section or disk 612, each of which defines a central opening 626. The first disk 610 includes a lip 644 at the opening 626, and the second disk 612 also includes a lip 646 at the opening 626. In the illustrated embodiment, the first disk 610 includes an angled surface 648 that slopes downward from the lip 644 toward the outer edge of the first disk 610. The second disk 612 also includes an angled surface 650 that slopes downward from the lip 646 toward the outer edge of the second disk 612. In the illustrated embodiment, both disks 610 and 612 have the same configuration of lips 644, 646 and angled surfaces 648, 650, so that the first disk 610 of the adjustable spacer 606 is the same as the second disk 612 of the adjustable spacer 606. As can be appreciated, implementing the same configuration for the first disk 610 and the second disk 612 of the adjustable spacer 606 provides simplified manufacturing. The adjustable spacer 606 also includes a tie 642. The cable tie 642 is generally a one-piece self-locking fastener that includes a slot 652 for receiving and securing an end 654 of the cable tie 642 to form a loop.

[0048] like Figure 6BAs best shown in , when the adjustable spacer 606 is assembled, the cable tie 642 is coupled to the first disk 610 and the second disk 612. Specifically, the end 654 of the cable tie 642 is inserted through the slot 652 to form a loop of a desired size that interfaces with the angled surface 648 of the first disk 610 and the angled surface 650 of the second disk 612. To adjust the thickness D1 of the adjustable spacer 606, the loop of the cable tie 642 can be adjusted (e.g., tightened) by pulling the end 654 through the slot 652. Specifically, to increase the thickness D1 of the adjustable spacer 606, the cable tie 642 is tightened, thereby creating a smaller loop that pushes against the angled surfaces 648, 650 in a wedge-like manner to move the first disk 610 away from the second disk 612. At the widest thickness (e.g., the tightest loop of the cable tie 642), the lips 644, 646 grip the cable tie 642 and prevent further tightening of the cable tie 642. Additionally, the thickness D1 of the adjustable spacer 606 can be adjusted by changing the width D2 of the cable tie 642. Similar to the screw-type adjustment mechanism 108 of the adjustable spacer 106 and the spring-type adjustment mechanism of the adjustable spacer 406, the wedge-type adjustment mechanism of the adjustable spacer 606 provides a continuous transition along the thickness range of the adjustable spacer 606 (e.g., when the cable tie 642 is tightened).

[0049] An exploded view of a transformer according to another example embodiment of the present disclosure is illustrated in Figure 7 700. The transformer 700 is similar to the transformer 100. However, instead of including the adjustable spacer 106, the transformer 700 includes an adjustable spacer 606. Similar to the transformer 100, the transformer 700 includes a plurality of windings 702 (e.g., primary windings and secondary windings) and a core 704 that magnetically couples the windings 702. As described above, the transformer 700 also includes the adjustable spacer 606 having an adjustable thickness D1 for mechanically separating and supporting the windings 702. Figure 7 , the adjustable spacer 606 is positioned between the windings 702 within the winding region of the transformer 700. In the illustrated embodiment, the adjustable spacer 606 is centrally positioned within the transformer 700. By doing so, the adjustable spacer 606 is able to position the windings 702 away from the air gap of the transformer 700. In this way, the fringing flux associated with the transformer 700 can be reduced (e.g., compared to a transformer including a spacer of a given thickness, etc.).

[0050] Figure 8A-B The assembly of the transformer 700 is illustrated. Specifically, Fig. 8AThe transformer 700 is illustrated assembled prior to adjusting the thickness of the adjustable spacer 606. Specifically, the winding 702, core 704, disk 610, tie 642, and disk 612 are aligned and assembled, however, the end 652 of the tie 642 has not yet been inserted through the slot 652. To ensure that the winding 702 is positioned away from the air gap of the transformer 700 (e.g., to reduce edge flux, etc.), the tie 642 is tightened by pulling the end 654 through the slot 652. As shown in FIG. Figure 8B As shown in FIG, after the cable tie 642 is tightened as desired, the end 654 can be removed (eg, cut) from the cable tie 642.

[0051] Fig. 9 A cross-sectional view of the transformer 700 is illustrated. As described above, the thickness D1 of the adjustable spacer 606 is adjusted by tightening the tie 642 (e.g., by pulling the end 654 through the slot 652). Specifically, when the tie 642 is tightened, the tie 642 pushes against the wedge-shaped disks 610, 612, which pushes the disks 610, 612 toward the winding 702, as indicated by arrows 900. In this way, the winding 702 is positioned away from the air gap of the transformer 700 and is fixed or secured in such a position because the tie 642 is self-locking (e.g., prevents loosening).

[0052] Figure 10A-10BAnother embodiment of an adjustable spacer 1006 is illustrated, the adjustable spacer 1006 including a wedge-shaped adjustment mechanism including at least one wedge-shaped pin 1056. Similar to the adjustable spacers 106, 406, 506, and 606, the adjustable spacer 1006 is suitable for use in an electrical component (e.g., a transformer, an inductor, etc.) including a transformer 100, for example, to separate and / or provide space between windings 102 included in the transformer 100. The adjustable spacer 1006 includes a first section or disk 1010 and a second section or disk 1012, each of which defines a central opening 1026. Similar to the wedge-shaped disks 610, 612, the first disk 1010 includes a lip 1044 at the opening 1026, and the second disk 1012 also includes a lip 1046 at the opening 1026. In the illustrated embodiment, the first disk 1010 includes an angled surface 1048 that slopes downward from the lip 1044 toward the outer edge of the first disk 1010. The second disk 1012 also includes an angled surface 1050 that slopes downward from the lip 1046 toward the outer edge of the second disk 1012. The adjustable spacer 1006 also includes at least one wedge pin 1056. Specifically, the adjustable spacer 1006 includes two wedge pins 1056, which include angled surfaces 1058 corresponding to the angled surface 1048 of the first disk 1010 and the angled surface 1050 of the second disk 1012.

[0053] refer to Fig. 10B, when the adjustable spacer 1006 is assembled, the wedge pin 1056 is coupled to the first disk 1010 and the second disk 1012. Specifically, the wedge pin 1056 is inserted or "wedged" between the first disk 1010 and the second disk 1012. Due to the angled surface 1058 of the wedge pin 1056, the thickness D1 of the adjustable spacer 1006 can be adjusted based on the amount of penetration of the wedge pin 1056 (e.g., the depth of the wedge pin 1056 inserted between the disks 1010, 1012). Specifically, when the wedge pin 1056 is inserted between the first disk 1010 and the second disk 1012, the angled surface 1058 of the wedge pin 1056 interacts with the angled surfaces 1048, 1050 to separate the first disk 1010 from the second disk 1012. Similar to the adjustable spacer 606, when the adjustable spacer 1006 is at its widest thickness (e.g., maximum penetration of the wedge pin 1056), the lips 1044, 1046 catch the cable tie wedge pin 1056 and prevent further penetration of the wedge pin 1056. In addition, the thickness D1 of the adjustable spacer 1006 can be adjusted by changing the width D2 of the wedge pin 1056. Similar to the screw-type adjustment mechanism 108 of the adjustable spacer 106 and the spring-type adjustment mechanism of the adjustable spacer 406, the wedge-type adjustment mechanism of the adjustable spacer 1006 provides a continuous transition along the thickness range of the adjustable spacer 1006 (e.g., when the wedge pin 1056 is inserted). In addition, although two wedge pins 1056 are included in the wedge-type adjustment mechanism of the adjustable spacer 1006, a greater or lesser number of wedge pins 1056 may be appropriate in other embodiments.

[0054] An exploded view of a transformer according to another example embodiment of the present disclosure is illustrated in Fig.11 1 and generally indicated by reference numeral 1100. Transformer 1100 is similar to transformer 100. However, instead of including adjustable spacers 106, transformer 1100 includes adjustable spacers 1006. Similar to transformer 100, transformer 1100 includes a plurality of windings 1102 (e.g., primary windings and secondary windings) and a core 1104 that magnetically couples windings 1102. As described above, transformer 1100 also includes adjustable spacers 1106 having an adjustable thickness D1 for mechanically separating and supporting windings 1102. Fig.11, the adjustable spacer 1106 is positioned between the windings 1102 within the winding region of the transformer 1100. In the illustrated embodiment, the adjustable spacer 1106 is centrally positioned within the transformer 1100. By doing so, the adjustable spacer 1106 can position the windings 1102 away from the air gap of the transformer 1100. In this way, the fringing flux associated with the transformer 1100 can be reduced (e.g., compared to a transformer including a spacer of a given thickness, etc.).

[0055] Figure 12A-12B The assembly of transformer 1100 is illustrated. Specifically, Fig. 12A The transformer 1100 is illustrated assembled prior to adjusting the thickness of the adjustable spacer 1006. Specifically, the winding 1102, core 1104, disk 1010, and disk 1012 are aligned and assembled, however, the wedge pin 1056 has not yet been inserted between the disks 1010, 1012. In order to ensure that the winding 1102 is positioned away from the air gap of the transformer 1100 (e.g., to reduce edge flux, etc.), the wedge pin 1056 is inserted between the disk 1010 and the disk 1012, as indicated by arrow 1200. Prior to insertion, the lips 1044 and the lips 1046 maintain a small gap between the outer edges of the disks 1010, 1012 so that the tip of the wedge pin 1056 can be inserted into the small gap. As shown in FIG. Fig. 12B As shown in , after the wedge pin 1056 is inserted to a desired depth (eg, a desired penetration amount of the wedge pin 1056 ), assembly of the transformer 1100 is complete.

[0056] Fig.13 A cross-sectional view of the transformer 1100 is illustrated. As described above, the thickness D1 of the adjustable spacer 1006 is adjusted by the amount of penetration of the wedge pin 1056 between the disks 1010, 1012. Specifically, when the wedge pin 1056 is inserted, the angled surface 1058 of the wedge pin 1056 pushes against the angled surfaces 1048, 1050 of the disks 1010, 1012 to adjust the disks 1010, 1012 toward the winding 1102, as indicated by the arrow 1300. In this way, the winding 1102 is positioned away from the air gap of the transformer 1100.

[0057] As described above, transformers 100, 700, and 1100 are suitable for use in a circuit board having any suitable circuit topology, such as a power supply. In some embodiments, one or more of transformers 100, 700, 1100 are used in a switch mode power supply (SMPS). Fig.141 illustrates an SMPS 1400 according to an example embodiment of the present disclosure, the SMPS 1400 including the transformer 100. In some embodiments, the SMPS 1400 includes the transformer 700 and / or the transformer 1100. Fig.14 As shown in FIG. 1 , SMPS 1400 includes a power supply circuit 1402 and a control circuit 1404. The power supply circuit 1402 includes an input 1406 for receiving an input voltage Vin and an output 1408 for providing an output voltage Vout. Fig.14 As shown in , the control circuit 1404 is coupled to the power circuit 1402 for regulating the output voltage Vout. Alternatively, the control circuit 1404 is coupled to the power circuit 1402 for regulating the input voltage Vin. The control circuit 1404 is configured to generate a control signal 1410. The components included in the SMPS 1400 are merely exemplary, and the transformer 100 (alternatively, the transformer 700, the transformer 1100, etc.) is contemplated for use in other circuit topologies, including any other suitable SMPS topologies.

[0058] The example embodiments described herein can facilitate the use of adjustable spacers within electrical components such as transformers or inductors, which provides advantages over using spacers of a given thickness (e.g., PCB spacers). For example, the adjustable spacer is adjustable within a range of thicknesses so that a single adjustable spacer can be used with multiple electrical components having the same core size but different air gaps. The ability to redefine the thickness of the adjustable spacer ensures compactness of materials within the electrical component to meet various material tolerances. The adjustable spacer also precisely permits stable leakage inductance. In addition, by keeping the windings within the electrical component away from the air gap, edge flux can be reduced.

[0059] The foregoing description of the embodiments has been provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. The individual elements or features of a specific embodiment are generally not limited to that specific embodiment, but are interchangeable where applicable and can be used in a selected embodiment, even if not specifically shown or described. It can also be varied in a variety of ways. Such variations should not be considered as departing from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A switch mode power supply comprising: at least one input; at least one output; as well as a power supply circuit coupled between the at least one input and the at least one output for converting an input voltage or current into an output voltage or current; The power circuit includes an electrical component having windings, an adjustable spacer positioned between the windings, and a core magnetically coupling the windings; The adjustable spacer includes an adjustable thickness; The adjustable spacer includes a first section and a second section, and the adjustable spacer also includes an adjustment mechanism connected to the first section and the second section, and the adjustment mechanism is configured to adjust the thickness of the adjustable spacer. The adjustment mechanism comprises a pair of threads configured to adjust the thickness, wherein the first segment comprises a first thread of the pair of threads, and the second segment comprises a second thread of the pair of threads, so that the first segment and the second segment can be screwed together and / or loosened. 2 . The power supply of claim 1 , wherein the first section and the second section each include a plurality of notches. 3 . The power supply of claim 1 , wherein the adjustment mechanism comprises at least one spring located on the first segment and / or the second segment. The power supply of claim 3 , wherein the at least one spring is a cantilever spring.

5. The power supply of claim 1, wherein the adjustment mechanism comprises a plurality of steps, in, The plurality of steps has at least one protruding step on the first section and at least one recessed step on the second section, and the at least one recessed step is configured to receive the at least one protruding step.

6. The power supply of claim 1 , further comprising a cable tie coupled to the adjustable spacer, wherein the cable tie is coupled to the first section and the second section when the adjustable spacer is assembled, and the cable tie is configured to adjust the thickness of the adjustable spacer by adjusting a loop of the cable tie by pulling a first end of the cable tie.

7. The power supply according to claim 1 further includes at least one wedge pin connected to the adjustable spacer, wherein the first segment includes an angled surface and the second segment includes an angled surface, and when the adjustable spacer is assembled, the at least one wedge pin is connected to the first segment and the second segment, including an angled surface corresponding to the first segment and the angled surface of the second segment, and the at least one wedge pin is configured to adjust the thickness of the adjustable spacer.

8. The power supply of claim 7, wherein the first segment is identical to the second segment.

9. The power supply of any one of claims 1-8, wherein the electrical component is an inductor.

10. The power supply of any one of claims 1-8, wherein the electrical component is a transformer.

11. A method of adjusting spacing between adjacent windings of an electrical component, the electrical component comprising: The first winding; Second winding; an adjustable spacer positioned between the first winding and the second winding and comprising a first disk having a first engagement structure and a second disk having a second engagement structure configured to mate with the first engagement structure; and a core, the core magnetically coupling the first winding and the second winding, the method comprising: rotating the first disk relative to the second disk to modify the rotational engagement of the first engagement structure with the second engagement structure; wherein a first space between the first disk and the second disk at a first rotational joint is different from a second space between the first disk and the second disk at a second rotational joint, The step of rotating the first disk relative to the second disk comprises: rotating the first disk relative to the second disk in a first rotational direction to increase a space between a surface of the first disk and a surface of the second disk from the first space to the second space; and The first disk is rotated relative to the second disk in a second rotational direction to reduce a space between the surface of the first disk and the surface of the second disk from the second space to the first space.

12. The method of claim 11, wherein the first engagement structure comprises a threaded structure; and The second engagement structure includes a threaded structure configured to cooperate with the threaded structure of the first engagement structure.

13. The method of claim 11, wherein the first engagement structure comprises a plurality of protruding steps; Wherein the second engagement structure comprises a plurality of recessed steps configured to cooperate with the plurality of protruding steps, the plurality of recessed steps comprising: a first set of recessed steps having a first depth; as well as a second set of recessed steps having a second depth different from the first depth; and The step of rotating the first disk relative to the second disk comprises: rotating the first disk relative to the second disk to position the plurality of protruding steps within the first set of recessed steps to separate a surface of the first disk from a surface of the second disk by the first space; as well as The first disk is rotated relative to the second disk to position the plurality of protruding steps within the second set of recessed steps, separating the surface of the first disk from the surface of the second disk by the second space.

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