transformer

Abstract

This invention provides a transformer, including a winding frame, a first coil, a second coil, a positioning member, and two iron cores. The winding frame has a winding section, a first baffle, a second baffle, and a terminal block. The winding section has through holes. The first baffle and the second baffle are respectively formed by horizontally extending from opposite ends of the winding section. The terminal block is connected to the second baffle. The first coil is wound around the winding section and electrically coupled to the terminal block. The second coil is sleeved around the first coil and spaced apart from each other. The second coil has multiple copper sheets located between the first baffle and the second baffle. The positioning member is provided corresponding to the winding frame for positioning the second coil. The two iron cores are respectively disposed on the second baffle and the positioning member of the winding frame, and the two iron cores pass through the through holes in the winding section.

Description

Technical Field

[0001] This invention relates to a transformer, and more particularly to a transformer used in electronic devices. Background Technology

[0002] Transformers used in high-wattage electronic devices typically employ high-frequency designs in their switching frequency selection to reduce size and increase power density. This allows the use of magnetic components with smaller effective cross-sectional areas, thereby reducing the transformer's size. Existing high-frequency transformers use an LLC structure combining windings and copper sheets. However, in existing high-frequency transformers, the copper sheets are stacked on the top and bottom sides of the windings, creating an air gap between the copper sheets and the windings. When the transformer is energized, this air gap generates leakage flux and forms a magnetic field, resulting in eddy current losses. Summary of the Invention

[0003] This invention provides a transformer that avoids air gaps between the windings and copper sheets, thereby reducing magnetic leakage and eddy current losses.

[0004] The transformer of the present invention includes a winding frame, a first coil, a second coil, a positioning member, and two iron cores. The winding frame has a winding section, a first baffle, a second baffle, and a terminal block. The winding section has through holes. The first baffle and the second baffle are respectively formed by horizontally extending from opposite ends of the winding section. The terminal block is connected to the second baffle. The first coil is wound around the winding section and electrically coupled to the terminal block. The second coil is sleeved around the first coil and spaced apart from it. The second coil has multiple copper sheets located between the first baffle and the second baffle. The positioning member is provided corresponding to the winding frame for positioning the second coil. The two iron cores are respectively disposed on the second baffle and the positioning member of the winding frame, and the two iron cores pass through the through holes in the winding section.

[0005] Based on the above, in the transformer of the present invention, the first coil is wound around the winding portion, and the second coil is sleeved outside the first coil. Therefore, the second coil is wound around the periphery of the first coil at intervals rather than stacked on top of each other, so that there is no air gap between the second coil and the first coil. Thus, the leakage magnetic phenomenon generated by the transformer after it is energized can be reduced, and the eddy current loss can be reduced. Attached Figure Description

[0006] The accompanying drawings are included to further illustrate the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0007] Figure 1A This is a perspective view of a transformer according to an embodiment of the present invention;

[0008] Figure 1B yes Figure 1A An exploded view of the transformer components;

[0009] Figure 1C yes Figure 1A A three-dimensional schematic diagram of the transformer's positioning component engaging with the second coil;

[0010] Figure 1D yes Figure 1A A three-dimensional schematic diagram of the second coil of the transformer wound around the winding frame;

[0011] Figure 1E yes Figure 1A A three-dimensional schematic diagram of the transformer's insulation layer surrounding the winding frame;

[0012] Figure 1F yes Figure 1A A three-dimensional schematic diagram of the second coil of the transformer;

[0013] Figure 2A This is a three-dimensional schematic diagram of the second coil according to another embodiment of the present invention;

[0014] Figure 2B This is a three-dimensional schematic diagram of the second coil according to another embodiment of the present invention;

[0015] Figure 2C This is a three-dimensional schematic diagram of the second coil according to another embodiment of the present invention;

[0016] Figure 3A This is a three-dimensional schematic diagram of the second coil combined with the cylindrical outer shell according to another embodiment of the present invention;

[0017] Figure 3B yes Figure 3A A three-dimensional schematic diagram of the second coil being fitted onto the winding frame;

[0018] Figure 4 This is a three-dimensional schematic diagram of the second coil combined with the cylindrical outer shell according to another embodiment of the present invention.

[0019] Explanation of icon numbers

[0020] 100: Transformer;

[0021] 110, 110c, 110d: Winding frame;

[0022] 111: Winding section;

[0023] 112, 112c: First baffle;

[0024] 113, 113c: Second baffle;

[0025] 114: Terminal block;

[0026] 1141: Electrical terminal;

[0027] 115: First positioning section;

[0028] 120: First coil;

[0029] 130, 130a, 130c, 130d: Second coil;

[0030] 131, 131c, 131d, 131e: Copper sheets;

[0031] 1311, 1311b, 1311e: Ring-shaped main body;

[0032] 1312, 1312b, 1312ce, 1312d, 1312e: Pins;

[0033] 131a: First copper sheet;

[0034] 132a: Second copper sheet;

[0035] 140: Positioning component;

[0036] 141: Annular plate;

[0037] 142: Positioning block;

[0038] 143: Second positioning part;

[0039] 144: Baffle plate;

[0040] 150: Iron core component;

[0041] 151: Shell;

[0042] 152: Column;

[0043] 160: Insulation layer;

[0044] 170: Circuit board;

[0045] 180c, 180d: Cylindrical outer shell;

[0046] E: End;

[0047] A1: First area;

[0048] A2: Second area;

[0049] AD: Axial direction;

[0050] H1, H2: Openings;

[0051] L1: Length of the first pin;

[0052] L2: Length of the second pin;

[0053] PG: Positioning groove;

[0054] RD: Radial;

[0055] TH: perforation;

[0056] TS: Top surface. Detailed Implementation

[0057] Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same element references are used in the drawings and description to denote the same or similar parts.

[0058] refer to Figure 1A and Figure 1B The transformer 100 of the present invention includes a winding frame 110, a first coil 120, a second coil 130, a positioning member 140, and two iron core members 150.

[0059] The winding frame 110 has a winding section 111, a first baffle 112, a second baffle 113, and a terminal block 114, wherein the winding frame 110 is made of insulating material. The winding section 111 has a through-hole TH and has a hollow tube structure, with the through-hole TH penetrating through the winding section 111. The first baffle 112 and the second baffle 113 are respectively formed by horizontally extending from opposite ends E of the winding section 111. The terminal block 114 is connected to the second baffle 113 and has a plurality of electrical terminals 1141. The plurality of electrical terminals 1141 extend from the outer edge of the terminal block 114 in a direction away from the winding frame 110, and the plurality of electrical terminals 1141 are bent at 90 degrees relative to the terminal block 114 to form an L-shaped appearance.

[0060] A first coil 120 is wound around the winding portion 111 of the winding frame 110 and electrically coupled to multiple electrical terminals 1141 of the terminal block 114. A second coil 130 is sleeved around the first coil 120 and spaced apart from it, that is, the second coil 130 surrounds the first coil 120 but does not contact it. The second coil 130 has multiple copper sheets 131 located between the first baffle 112 and the second baffle 113. A positioning member 140 is provided corresponding to the winding frame 110 to position the multiple copper sheets 131 of the second coil 130. Two iron cores 150 are respectively disposed on the second baffle 113 and the positioning member 140 of the winding frame 110, and the two iron cores 150 pass through the through holes TH of the winding portion 111 and are electrically coupled to each other.

[0061] refer to Figures 1C to 1E The transformer 100 also includes an insulating layer 160 surrounding the first coil 120 and blocking the second coil 130, so that the first coil 120 is insulated from the second coil 130. In other words, the insulating layer 160 is located between the first coil 120 and the second coil 130 to prevent the first coil 120 and the second coil 130 from contacting each other and conducting electricity.

[0062] refer to Figure 1B , Figures 1D to 1F In this embodiment, the first area A1 of the first baffle 112 is smaller than the second area A2 of the second baffle 113. Therefore, the opening H1 of the second coil 130 is suitable for passing through the first baffle 112 and the second coil 130 abuts against the second baffle 113, thereby surrounding the winding frame 110 and completely covering the first coil 120. The second coil 130 and the first coil 120 overlap each other in the radial direction RD of the winding frame 110. The assembly method of overlapping the first coil 120 (primary side coil) and the second coil 130 (secondary side coil) in the radial direction RD adopted in this embodiment makes it possible to eliminate the air gap between the second coil 130 and the first coil 120, thus reducing magnetic leakage.

[0063] Reference Figure 1F Each copper sheet 131 of the second coil 130 has an annular body 1311 and a plurality of leads 1312. The plurality of leads 1312 extend outward from the annular body 1311 and are parallel to each other. In this embodiment, the plurality of leads 1312 have a straight appearance and are perpendicular to the axis AD of the winding frame 110. The second coils 130 are stacked together along the axis AD passing through the winding portion 111, and the plurality of leads 1312 together form two positioning grooves PG.

[0064] refer to Figure 1A and Figure 1B The winding frame 110 has two first positioning parts 115, which are respectively disposed on the second baffle 113 and the terminal block 114, and the two first positioning parts 115 are engaged with one of the corresponding iron core members 150 to prevent the winding frame 110 and the corresponding iron core member 150 from shaking or separating.

[0065] refer to Figure 1A and Figure 1B The positioning member 140 includes an annular plate 141, two positioning blocks 142, two second positioning portions 143, and a blocking plate 144. The annular plate 141 has an opening H2 corresponding to a through hole TH located in the winding portion 111. The two positioning blocks 142 are disposed on the outer edge of the annular plate 141 and extend toward the second blocking plate 113. The two second positioning portions 143 are disposed on the top surface TS of the annular plate 141. The blocking plate 144 is disposed on the outer edge of the annular plate 141 and opposite to the two positioning blocks 142.

[0066] Reference Figure 1CTwo positioning blocks 142 are inserted into the two positioning slots PG of the second coil 130, and the two positioning blocks 142 are used to limit the multiple leads 1312 of the multiple copper sheets 131 to prevent the multiple copper sheets 131 from separating from each other and the leads 1312 from intersecting. Two second positioning parts 143 are engaged with the corresponding iron core 150. The baffle plate 144 partially covers the second coil 130. Furthermore, through the limiting effect of the baffle plate 144 and the two second positioning parts 143, the multiple annular bodies 1311 of the multiple copper sheets 131 can be restricted on the second baffle plate 113.

[0067] refer to Figure 1A and Figure 1B Each of the plurality of iron core components 150 has a housing 151 and a column 152. The column 152 is disposed within the housing 151, wherein the column 152 of one iron core component 150 passes through the positioning member 140 and enters the through hole TH of the winding frame 110. The column 152 of the other iron core component 150 passes through the second baffle 113 and enters the through hole TH of the winding frame 110. In this embodiment, the number of the plurality of iron core components 150 is two. The two housings 151 of the two iron core components 150 are electrically coupled to each other and cover the second coil 130, and the two housings 151 are offset between the two second positioning portions 143 and the baffle 144 of the positioning member 140. The two columns 152 of the two iron core components 150 are electrically coupled to each other in the through hole TH, thus the two iron core components 150 form a circuit.

[0068] refer to Figure 1A and Figure 1B It also includes a circuit board 170, and a plurality of electrical terminals 1141 disposed on the corresponding iron core 150 and electrically coupled to the terminal block 114.

[0069] Figure 2A This is a three-dimensional schematic diagram of the second coil according to another embodiment of the present invention.

[0070] refer to Figure 2A In this embodiment, the plurality of copper pieces of the second coil 130a includes at least one first copper piece 131a and at least one second copper piece 132a. The first lead length L1 of the at least one first copper piece 131a is different from the second lead length L2 of the at least one second copper piece 132a. In this embodiment, the lead length L1 is greater than the lead length L2; in other embodiments, the first lead length L1 is greater than the second lead length L2.

[0071] Furthermore, the second coil in this embodiment uses different pin lengths, making it suitable for electronic devices of different specifications.

[0072] Figure 2B This is a three-dimensional schematic diagram of the second coil according to another embodiment of the present invention.

[0073] refer to Figure 2BIn this embodiment, each copper sheet 131b of the second coil has an annular body 1311b and a plurality of pins 1312b, the plurality of pins 1312b extending from the annular body 1311b and having a bent appearance.

[0074] Furthermore, the second coil in this embodiment uses a bent-shaped lead, making it suitable for electronic devices of different specifications.

[0075] Figure 2C This is a three-dimensional schematic diagram of the second coil according to another embodiment of the present invention.

[0076] refer to Figure 2C In this embodiment, each copper sheet 131e has an annular body 1311e and two pins 1312e. The two ends of the annular body 1311e are respectively formed into two pins 1312e and the two pins 1312e are spaced apart from each other.

[0077] Figure 3A This is a three-dimensional schematic diagram of the second coil combined with the cylindrical outer shell according to another embodiment of the present invention. Figure 3B yes Figure 3A A three-dimensional schematic diagram of the second coil being mounted on the winding frame.

[0078] refer to Figure 3A and Figure 3B The system also includes a cylindrical outer shell 180c, within which a second coil 130c is disposed. Furthermore, multiple copper plates 131c of the second coil 130c are stacked on top of each other within the cylindrical outer shell 180c, and these copper plates 131c are fitted onto a winding frame 110c and positioned between a first baffle 112c and a second baffle 113c. Multiple leads 1312c of the copper plates 131c protrude from the cylindrical outer shell 180c. The cylindrical outer shell 180c is made of insulating material, thereby concentrating the magnetic field generated by the second coil 130c within the cylindrical outer shell 180c, further reducing magnetic leakage.

[0079] Figure 4 This is a three-dimensional schematic diagram of the second coil combined with the cylindrical outer shell according to another embodiment of the present invention.

[0080] refer to Figure 4The system also includes multiple cylindrical shells 180d, with multiple copper plates 131d of the second coil 130d respectively disposed within the corresponding cylindrical shells 180d. Furthermore, the multiple copper plates 131d of the second coil 130d are stacked within the multiple cylindrical shells 180d, and are fitted onto a winding frame 110d and positioned between a first baffle 112d and a second baffle 113d. The multiple cylindrical shells 180d are spaced apart from each other. Multiple leads 1312d of the multiple copper plates 131d protrude from the corresponding cylindrical shells 180d. The cylindrical shells 180d are made of insulating material, thereby concentrating the magnetic field generated by the second coil 130d within the cylindrical shells 180d, further reducing magnetic leakage.

[0081] In summary, in the transformer of the present invention, the first coil is wound around the winding portion, and the second coil is sleeved outside the first coil. Therefore, the second coil is wound around the periphery of the first coil at intervals rather than stacked on top of each other, so that there is no air gap between the second coil and the first coil. Thus, the leakage magnetic phenomenon generated after the transformer is energized can be avoided, and eddy current losses can be reduced.

[0082] Furthermore, in the transformer of the present invention, the first coil (primary coil) can be electrically connected to the circuit board through multiple electrical terminals of the terminal block, replacing the existing flying wire connection method. The second coil (secondary coil) uses multiple stacked copper sheets wrapped around the first coil, which has the technical advantages of reducing power consumption and lowering operating temperature compared to transformers of the prior art.

Claims

1. A transformer, characterized in that, include: A winding frame has a winding section, a first baffle, a second baffle, and a terminal block. The winding section has a through hole. The first baffle and the second baffle are respectively formed by horizontally extending from opposite ends of the winding section, and the terminal block is connected to the second baffle. A first coil is wound around the winding portion and electrically coupled to the terminal block; The second coil is sleeved outside the first coil and spaced apart from each other. The second coil has a plurality of copper sheets, which are located between the first baffle and the second baffle. A positioning element, corresponding to the winding frame, is used to position the second coil; and Two iron core components are respectively disposed on the second baffle and the positioning component of the winding frame, and the two iron core components pass through the through holes of the winding section. The positioning member includes an annular plate, two positioning blocks, two second positioning portions, and a blocking plate. The annular plate has an opening for the through hole located in the winding portion. The two positioning blocks are disposed on the outer edge of the annular plate and extend toward the second blocking plate. The two second positioning portions are disposed on the top surface of the annular plate. The blocking plate is disposed on the outer edge of the annular plate and is relative to the two positioning blocks.

2. The transformer according to claim 1, characterized in that, The winding frame has two first positioning parts, which are respectively disposed on the second baffle and the terminal block, and the two first positioning parts are engaged with the corresponding iron core.

3. The transformer according to claim 1, characterized in that, The two positioning blocks are inserted through the second coil, the two second positioning parts are engaged with the corresponding iron core parts, and the blocking plate partially covers the second coil.

4. The transformer according to claim 1, characterized in that, It also includes an insulating layer that surrounds the first coil and blocks the second coil, so that the first coil is insulated from the second coil.

5. The transformer according to claim 1, characterized in that, Each of the copper sheets has an annular body and multiple pins, which extend outward from the annular body and are parallel to each other.

6. The transformer according to claim 5, characterized in that, The plurality of copper sheets of the second coil are stacked on top of each other along the axial direction of the winding portion, and the plurality of pins together form two positioning grooves.

7. The transformer according to claim 1, characterized in that, The plurality of copper sheets include at least one first copper sheet and at least one second copper sheet, wherein the length of the first lead of the at least one first copper sheet is different from the length of the second lead of the at least one second copper sheet.

8. The transformer according to claim 1, characterized in that, Each of the copper sheets has an annular body and a plurality of pins, the plurality of pins extending from the annular body and having a bent appearance.

9. The transformer according to claim 1, characterized in that, Each of the copper sheets has two pins at its two ends, and the two pins are spaced apart from each other.

10. The transformer according to claim 1, characterized in that, Each of the plurality of iron core components has a housing and a column, the column being disposed within the housing. The column of one iron core component passes through the positioning member and enters the through hole of the winding frame, while the column of the other iron core component passes through the second baffle and enters the through hole of the winding frame. The two housings of the two iron core components are electrically coupled to each other and cover the second coil.

11. The transformer according to claim 1, characterized in that, The first area of ​​the first baffle is smaller than the second area of ​​the second baffle.

12. The transformer according to claim 1, characterized in that, It also includes a circuit board disposed on the corresponding iron core and electrically coupled to the terminal block.

13. The transformer according to claim 1, characterized in that, It also includes a cylindrical housing, in which the second coil is disposed, and the plurality of pins of the plurality of copper sheets protrude from the cylindrical housing.

14. The transformer according to claim 1, characterized in that, It also includes multiple cylindrical housings, with the multiple copper sheets of the second coil respectively disposed in the corresponding multiple cylindrical housings.

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