Coil device
By designing main middle legs, secondary middle legs, and outer legs on the winding frame and core structure, the problems of miniaturization and increased AC resistance of leakage flux transformers are solved, leakage flux generation and inductance consistency are achieved, and copper loss is reduced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- TDK CORP
- Filing Date
- 2022-11-25
- Publication Date
- 2026-08-04
AI Technical Summary
Existing leakage transformers do not have a distance between the primary and secondary coils, making it difficult to miniaturize the transformer and to ensure leakage flux and suppress the increase of AC resistance while maintaining miniaturization.
The design employs a winding frame and core structure. By winding the first and second coil sections on the winding frame and setting the main middle leg, secondary middle leg, and outer leg on the core, leakage flux is ensured while suppressing the increase of AC resistance.
It achieves miniaturization of the coil device, suppresses the increase of AC resistance, makes it easy to adjust the turns ratio of the primary and secondary coils, ensures consistent inductance, and prevents pin damage.
Smart Images
Figure CN116259470B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates, for example, to a coil device suitable for use as a leakage transformer. Background Technology
[0002] As a composite transformer that combines the functions of a transformer with those of a choke coil, a leakage flux transformer can be used. In a leakage flux transformer, since the leakage flux functions as a choke coil, the structure of the choke coil can be omitted, which has the advantage of contributing to the miniaturization of the transformer.
[0003] Patent document 1 discloses a horizontal leakage magnetic transformer in which a secondary coil is arranged inside a primary coil and a vertical leakage magnetic transformer in which the primary coil and the secondary coil are coaxially wound and arranged vertically.
[0004] However, regardless of the type of transformer, without setting a certain distance between the primary and secondary coils, leakage flux cannot be ensured, making it difficult to achieve transformer miniaturization.
[0005] Existing technical documents
[0006] Patent documents
[0007] Patent Document 1: Japanese Patent Application Publication No. 2005-158927 Summary of the Invention
[0008] The technical problem the invention aims to solve
[0009] The present invention was made in view of the actual situation, and its object is to provide a coil device that can ensure leakage flux and achieve miniaturization.
[0010] Means for solving technical problems
[0011] To achieve the above objectives, the coil device according to the present invention includes: a winding frame; a first conductor having a first coil portion wound on the winding frame; a second conductor having a second coil portion wound on the winding frame; and a core mounted on the winding frame, the core including: a base extending along a first axis direction; a main center leg disposed approximately at the center of the base in the first axis direction; a first auxiliary center leg disposed on one side of the base relative to the main center leg in the first axis direction; and a second auxiliary center leg disposed on the other side of the base in the first axis direction, the main center leg being disposed inside the first coil portion and the second coil portion, the first auxiliary center leg being disposed inside the first coil portion and outside the second coil portion, and the second auxiliary center leg being disposed inside the second coil portion and outside the first coil portion.
[0012] By employing this structure, even when the coils are close to each other, leakage flux can be generated through the secondary center leg, ensuring leakage flux and enabling miniaturization of the coil assembly. Furthermore, this structure suppresses AC resistance and inhibits the increase of copper losses.
[0013] Furthermore, this structure also makes it easy to adjust the turns ratio of the primary and secondary coils. For example, in existing horizontal leakage transformers, it is difficult to ensure leakage flux while maintaining a small size when the turns ratio of each coil is 1:1 and the inductance of each coil is consistent. However, according to the structure described above, leakage flux can be easily ensured even when the turns ratio of each coil is 1:1 and the inductance of each coil is consistent.
[0014] Preferably, the core has a first outer leg and a second outer leg disposed on the base, a first secondary middle leg disposed between the first outer leg and the main middle leg, and a second secondary middle leg disposed between the second outer leg and the main middle leg. The first outer leg is disposed outside the first coil portion, and the second outer leg is disposed outside the second coil portion. With this structure, each coil portion is located between the outer legs, and miniaturization of the coil assembly is achieved.
[0015] Preferably, the core comprises: a first core portion including at least a first base that is part of the aforementioned base, and a second core portion including at least another part of the aforementioned base and a second base that is substantially parallel to the first base. The first core portion and the second core portion clamp the first coil portion and the second coil portion along the winding axis of the first coil portion. By adopting such a structure, each coil is located between the bases, and miniaturization of the coil device can be achieved.
[0016] Preferably, the winding frame has a first winding portion on which the first coil portion is wound, a second winding portion on which the second coil portion is wound, and a winding spacer flange separating the first winding portion and the second winding portion. The first winding portion has a first main through hole for arranging the main center leg and a first secondary through hole for arranging the first auxiliary center leg. The second winding portion has a second main through hole for arranging the main center leg and a second secondary through hole for arranging the second auxiliary center leg. The first main through hole communicates with the second main through hole. In this structure, the first conductor and the second conductor can be insulated, and each conductor can be reliably insulated from the core.
[0017] Preferably, the combined cross-sectional area of the main middle leg, the first outer leg, and the second outer leg is approximately the same. More preferably, the cross-sectional area of the main middle leg is larger than the cross-sectional area of the first secondary middle leg.
[0018] Preferably, the core is symmetrical about an axis of symmetry orthogonal to the first axis. By adopting such a structure, it is easy to make the turns ratio of the first coil section to the second coil section 1:1, and further, it is also easy to make the inductance of the coils consistent.
[0019] Alternatively, a first gap can be formed in the foot of the first pair. This first gap allows for adjustment of magnetic leakage. Furthermore, a second gap can be formed in the main foot, preferably with the first gap being longer than the second gap. These gaps prevent damage to the foot.
[0020] Preferably, the first portion and the second portion of the core are symmetrical along the winding axis of the first coil portion. Alternatively, the core may be divided along a second axis perpendicular to both the first axis and the winding axis of the first coil portion. Attached Figure Description
[0021] Figure 1 This is a general perspective view showing the structure of a coil device according to one embodiment of the present invention.
[0022] Figure 2A Looking at it from another perspective Figure 1 A schematic diagram of a portion of the coil device involved.
[0023] Figure 2B Looking at it from another angle Figure 1 A schematic diagram of a portion of the coil device involved.
[0024] Figure 2C yes Figure 2A The cross-sectional view at the IIC-IIC line is shown.
[0025] Figure 3 It means Figure 1 A top view of a portion of the structure of the coil device in question.
[0026] Figure 4A It means Figure 1 A general three-dimensional view of the structure of the winding frame of the coil device involved.
[0027] Figure 4B It means Figure 4A A top view of the structure of the winding frame involved.
[0028] Figure 4C It means Figure 4A Rear view of the structure of the winding frame involved.
[0029] Figure 4D yes Figure 4A A cross-sectional view of the IVD-IVD line of the winding frame involved.
[0030] Figure 4E yes Figure 4A A cross-sectional view of the IVE-IVE line of the winding frame involved.
[0031] Figure 5A It means Figure 1 An exploded perspective view of the core structure of the coil device involved.
[0032] Figure 5B It means Figure 1 A front view of the core structure of the coil device involved.
[0033] Figure 6 It means Figure 1 A general three-dimensional diagram of the wire structure of the coil device involved.
[0034] Figure 7 It means Figure 1 A general three-dimensional view of the structure of the housing of the coil device involved.
[0035] Symbol Explanation
[0036] 1 Transformer
[0037] 10 winding frames
[0038] 12 First lead wire lead-out socket
[0039] 13 Separating Protrusions
[0040] 14a, 14b First lead mounting section
[0041] 14a1, 14b1 First groove
[0042] 16a, 16b First Passage Section
[0043] 22 Second lead-out connector
[0044] 24a, 24b Second lead mounting section
[0045] 24a1, 24b1, second groove
[0046] 26 Second Passage Section
[0047] 30 First end spacer flange
[0048] 31 First insertion hole
[0049] 32 Second end spacer flange
[0050] 32a, 32b convex portions
[0051] 33 Second insertion hole
[0052] 34-wound spacer flange
[0053] 35 incisions
[0054] 40 First winding section
[0055] 41 weeks
[0056] 42 First Main Through Hole
[0057] 44 First through hole
[0058] 46 First Insulating Wall
[0059] 47, 48 segments
[0060] 50 Second winding section
[0061] 51 weeks
[0062] 52 Second Main Through Hole
[0063] 54 Second Through Hole
[0064] 56. Second Insulating Wall
[0065] 57, 58 segmented pieces, 60a, 60b cores
[0066] 61a, 61b split core
[0067] 611a and 611b dividing surfaces
[0068] 62a base (core part 1)
[0069] 62b base (core part 2)
[0070] 63a1, 63a2, 63b1, 63b2 inclined surfaces, 64a, 64b main middle feet
[0071] 65a and 65b end faces
[0072] 66a1, 66b1 First pair of middle feet
[0073] 66a2, 66b2 Second pair of middle feet
[0074] 67a1 and 67b1 end faces
[0075] 67a2 and 67b2 end faces
[0076] 68a1, 68b1 First outer leg
[0077] 68a2, 68b2 second outer leg
[0078] 69a1, 69b1 end faces
[0079] 69a2, 69b2 end face 70 first conductor
[0080] 72a, 72b First lead section
[0081] 73 connection terminals
[0082] 74 First coil section
[0083] 76. Outer side of coil 1
[0084] 78 Inner side of the first coil 80 Second conductor
[0085] 82a, 82b second lead section
[0086] 83 connection terminal
[0087] 84 Second Coil Section
[0088] 86. Outer side of the second coil
[0089] 88. Inner side of the second coil
[0090] 90 shell
[0091] 91 Fixing Part
[0092] 92 base plate
[0093] Gap 100a, 100b (Gap 1)
[0094] Gap 101 (Second Gap) Detailed Implementation
[0095] The present invention will now be described based on the embodiments shown in the accompanying drawings.
[0096] like Figure 1 As shown, the transformer 1, which is the coil device involved in this embodiment, can be used as a leakage transformer, for example, and can be used in on-board chargers for electric vehicles, general power supplies, etc.
[0097] like Figure 1 As shown, the transformer 1 has a first conductor 70 and a second conductor 80, a winding frame 10 for winding the conductors, cores 60a and 60b clamping the winding frame 10 along the Z-axis, and a housing 90 that houses these components. Furthermore, in the figure, the X-axis, Y-axis, and Z-axis are perpendicular to each other, with the Z-axis corresponding to the height (thickness) of the transformer 1. In this embodiment, the surface of the transformer 1 is located below the Z-axis direction. Additionally, the X-axis aligns with the extending direction of the base 62b of the core 60b. Furthermore, the Y-axis aligns with the arrangement direction of the segmented cores 61b and 61b of the core 60b.
[0098] Furthermore, in the instruction manual, the direction in which core 60b is configured is sometimes referred to as "above," and the direction in which core 60a is configured is sometimes referred to as "below." Also, in the instruction manual, the side closer to the center of transformer 1 is sometimes referred to as "inner side," and the side farther from the center is sometimes referred to as "outer side."
[0099] In this embodiment, such as Figure 7 As shown, the outer casing 90 is formed of a plate-like member, open at the top in the Z-axis direction, and a base plate 92 is formed at the bottom in the Z-axis direction. Fixing portions 91 are formed at the four corners of the base plate 92. The outer casing 90 is preferably made of a metal with excellent heat dissipation, such as aluminum, copper, or iron, but it can also be made of PPS, PET, PBT, etc. The base plate 92 contacts the lower end face of the core 60a in the Z-axis direction, which will be described later; therefore, the base plate 92 is preferably made of a material with excellent heat dissipation. Cooling devices such as cooling pipes or cooling fans can be installed below the outer casing 90, either through the base plate 92 or directly.
[0100] Alternatively, the interior of the outer casing 90 may be filled with a heat-dissipating resin. There are no particular limitations on the heat-dissipating resin; however, a resin with excellent heat dissipation properties, such as a thermal conductivity of 0.5 to 5, and more preferably 1 to 3 W / m·K, is preferred. Examples of resins with excellent heat dissipation properties include silicone resins, polyurethane resins, and epoxy resins.
[0101] Furthermore, the heat-dissipating resin in this embodiment preferably absorbs deformation even if the cores 60a, 60b or the winding frame 10 deform due to heat, so that the cores 60a, 60b do not generate excessive stress. Potting resin is an example of such a resin.
[0102] like Figure 1 As shown, in this embodiment, core 60a has become Figure 5A The base 62a of the first core portion is shown. The base 62a is disposed below the winding frame 10 in the Z-axis direction. The core 60b has a base 62b that becomes the second core portion. The base 62b is disposed above the winding frame 10 in the Z-axis direction. In this embodiment, the material of each core 60a and 60b can include soft magnetic materials such as metals and ferrites, but is not particularly limited.
[0103] Cores 60a and 60b are symmetrical along the Z-axis. For example... Figure 5A As shown, core 60a can be separated into two segmented cores 61a and 61a with the same shape at the dividing surface 611a. Core 60b can be separated into two segmented cores 61b and 61b with the same shape at the dividing surface 611b. In this embodiment, all segmented cores 61a and 61a and 61b and 61b are of the same shape.
[0104] The following describes the dividing core 61a; the description of the dividing core 61b will be omitted unless otherwise specified. The dividing core 61a is symmetrical about the axis of symmetry (Z-axis) orthogonal to the X-axis direction.
[0105] like Figure 5A As shown, the base 62a of the dividing core 61a extends along the X-axis. On the outer side of the base 62a, which is closer to the center in the Y-axis direction, there are central inclined surfaces 63a1 and 63a1 facing the X-axis.
[0106] At the base 62a, a main central leg 64a is formed that protrudes upward in the Z-axis direction. The main central leg 64a is located approximately at the center in the X-axis direction where the base 62a is positioned.
[0107] Furthermore, a first outer leg portion 68a1 and a second outer leg portion 68a2 protruding upward in the Z-axis direction are formed on the base 62a. The first outer leg portion 68a1 is disposed at one end of the base 62a in the X-axis direction, and the second outer leg portion 68a2 is disposed at the other end of the base 62a in the X-axis direction.
[0108] Furthermore, at the base 62a, a first secondary middle leg 66a1 and a second secondary middle leg 66a2 protrude upward in the Z-axis direction. The first secondary middle leg 66a1 is disposed between the first outer leg 68a1 and the main middle leg 64a. The second secondary middle leg 66a2 is disposed between the second outer leg 68a2 and the main middle leg 64a.
[0109] like Figure 1 As shown, the dividing core 61a is positioned below the winding frame 10 in the Z-axis direction, and the dividing core 61b is positioned below the winding frame 10 in the Z-axis direction. Figure 5B As shown, the end faces 69a1 and 69b1 of the first outer legs 68a1 and 68b1 are opposite each other along the Z-axis, and the end faces 69a2 and 69b2 of the second outer legs 68a2 and 68b2 are opposite each other along the Z-axis.
[0110] like Figure 5B As shown, a gap 100a (first gap) with a distance T1 is formed between the Z-axis end face 67a1 of the first middle leg 66a1 and the Z-axis end face 67b1 of the first middle leg 66b1. A gap 100b (first gap) with a distance T1 is formed between the Z-axis end face 67a2 of the second middle leg 66a2 and the Z-axis end face 67b2 of the second middle leg 66b2.
[0111] A gap 101 (second gap) with a distance T2 is formed between the end face 65a along the Z-axis of the main middle leg 64a and the end face 65b along the Z-axis of the main middle leg 64b. Figure 5B As shown, T1 is longer than T2.
[0112] In this embodiment, Figure 3 The cross-sectional area S1 of the main middle leg 64a along the Z-axis is larger than the cross-sectional area S2 of the first secondary middle leg 66a1 and the second secondary middle leg 66a2 along the Z-axis. Furthermore, the sum S3 of the cross-sectional area S1 of the main middle leg 64a and the cross-sectional areas S3 of the first outer leg 68a1 and the second outer leg 68a2 along the Z-axis is approximately the same.
[0113] like Figure 4C As shown, the winding frame 10 has a first end spacer flange 30, a second end spacer flange 32, and a winding spacer flange 34. A first winding portion 40, which forms the main body of the winding frame, is formed between the first end spacer flange 30 and the winding spacer flange 34. A second winding portion 50, which also forms the main body of the winding frame, is formed between the second end spacer flange 32 and the winding spacer flange 34. The winding frame 10 may be made of plastics such as PPS, PET, PBT, LCP, or nylon, or may be made of other insulating components.
[0114] like Figure 4A As shown, the first end spacer flange 30 is positioned above the first winding portion 40 in the Z-axis direction. A first lead wire outlet seat 12 is formed on the outer side of the first end spacer flange 30, relative to the center of the Y-axis. Conical surfaces 12a, 12a inclined towards the center of the X-axis are formed on the inner side of the first lead wire outlet seat 12 along the Y-axis. The conical surfaces 12a, 12a are inclined towards the center of the X-axis. Figure 5A The base 62b of a segmented core 60b shown is formed along the center of the Y-axis by contacting the outer inclined surfaces 63b1, 63b1.
[0115] like Figure 4A As shown, the first lead outlet 12 has first passage portions 16a and 16b extending along the Z-axis, and a separation protrusion 13 is formed between the first passage portions 16a and 16b. First lead mounting portions 14a and 14b are formed on the outer side of the center in the Y-axis direction of the first lead outlet 12. First groove portions 14a1 and 14b1 are formed on the first lead mounting portions 14a and 14b, extending on the outer side of the center in the Y-axis direction. The inner side of the first groove portions 14a1 and 14b1 in the Y-axis direction is connected to the upper side of the first passage portions 16a and 16b in the Z-axis direction.
[0116] like Figure 4A As shown, a second lead outlet 22 is formed on the first end spacer flange 30. The second lead outlet 22 is disposed outside the center in the Y-axis direction opposite to the first lead outlet 12.
[0117] On the inner side of the second lead-out seat 22 along the Y-axis, there are tapered surfaces 22a, 22a inclined towards the center of the X-axis. The tapered surfaces 22a, 22a are aligned with... Figure 5A The base 62b of another segmented core 60b shown is formed along the center of the Y-axis with the outer inclined surfaces 63b2, 63b2 in contact.
[0118] like Figure 4A As shown, the second lead outlet 22 has a second passage portion 26 extending along the Z-axis. On the outer side of the center in the Y-axis direction of the second lead outlet 22, second lead mounting portions 24a and 24b are formed.
[0119] like Figure 4B As shown, second grooves 24a1 and 24b1 are formed in the second lead carrier portions 24a and 24b. The second groove 24a1 is L-shaped, having a first portion along the X-axis and a second portion along the Y-axis. The first portion of the second groove 24a1 is connected to the second passage portion 26, and the second portion of the second groove 24a1 extends outward toward the center in the Y-axis direction. The first portion of the second groove 24b1 is connected to the upper part of the second passage portion 26 in the Z-axis direction.
[0120] A first insertion hole 31 is formed on the first end spacer flange 30. The first insertion hole 31 and Figure 5A The shapes of the second set of middle feet 66b2 and 66b2 are corresponding. The first insertion hole 31 is arranged to overlap with the second set of through hole 54. The second set of middle feet 66b2 is inserted into the first insertion hole 31.
[0121] like Figure 4C As shown, the first winding section 40 extends along the Z-axis. The central axis O1 of the first winding section 40 ( Figure 2B The winding shaft of the first coil portion 74 shown is positioned on the outer side along the X-axis relative to the central axis O of the first main through hole 42. A circumferential surface 41 of the first winding portion 40 is formed... Figure 2B The first coil section 74 is shown. In addition, the central axis O1 and the central axis O are parallel to the Z-axis.
[0122] like Figure 4D As shown, the first winding portion 40 has a first main through hole 42. (As indicated...) Figure 2C As shown, the first main through hole 42 is connected to the second main through hole 52. The first main through hole 42 and... Figure 5A The shapes of the main middle feet 64b and 64b are corresponding. For example... Figure 4D As shown, segmented pieces 47, 47 are formed in the first main through hole 42. The segmented pieces 47, 47 and... Figure 5A The dividing surfaces 611b of the main middle legs 64b and 64b shown abut each other, dividing the dividing cores 61b and 61b along the Y-axis.
[0123] like Figure 4D As shown, the first winding portion 40 has a first through hole 44. (As indicated...) Figure 2C As shown, the first through hole 44 is connected to the winding spacer flange 34. The first through hole 44 is connected to... Figure 5A The shapes of the first pair of legs 66b1 and 66b1 correspond. For example... Figure 4D As shown, a dividing piece 48 is formed in the first through hole 44. The dividing piece 48 and... Figure 5A The dividing surfaces 611b of the first set of middle feet 66b1 and 66b1 abut each other, dividing the dividing cores 61b and 61b along the Y-axis.
[0124] like Figure 4D As shown, a first insulating wall 46 is formed between the first main through hole 42 and the first secondary through hole 44. The first insulating wall 46 is disposed in... Figure 5A The main middle legs 64b, 64b shown are insulated from the first secondary middle legs 66b1, 66b1.
[0125] like Figure 4C As shown, a winding spacer flange 34 is formed below the first winding portion 40 in the Z-axis direction. A cutout 35 is formed on the winding spacer flange 34 at a position corresponding to the position below the second passage portion 26 in the Z-axis direction. That is, the cutout 35 is offset outward from the center in the X-axis direction. Figure 2B As shown, the second lead portions 82a and 82b are led out from the second coil portion 84 in the Z-axis direction through the cutout 35 and the second passage portion 26.
[0126] like Figure 4C As shown, the second winding portion 50 extends along the Z-axis. The central axis O2 of the second winding portion 50 ( Figure 2B The winding shaft of the second coil section 84 shown is relative to the center line O of the second main through hole 52. Figure 4A The central axis O2 of the main through hole 42 shown is positioned on the outer side along the X-axis. Additionally, the central axis O2 is parallel to the Z-axis.
[0127] In this embodiment, the second winding portion 50 has a shape corresponding to the first winding portion 40. The first winding portion 40 and the second winding portion 50 are respectively... Figure 4D and Figure 4E The central axis O shown is symmetrical to the central line Lx, which is parallel to the X-axis and is the axis of symmetry.
[0128] like Figure 4E As shown, the second winding portion 50 has a second main through hole 52. (As indicated...) Figure 2C As shown, the second main through hole 52 and Figure 5A The shapes of the main middle feet 64a and 64a are corresponding. For example... Figure 4E As shown, segmented pieces 57, 57 are formed in the second main through hole 52. The segmented pieces 57, 57 and... Figure 5AThe dividing surfaces 611a of the main middle legs 64a and 64a shown abut each other, and the dividing cores 61a and 61a are divided along the Y-axis.
[0129] like Figure 4E As shown, the second winding portion 50 has a second through hole 54. (As indicated...) Figure 2C As shown, the second through hole 54 is connected to the winding spacer flange 34. The second through hole 54 is connected to... Figure 5A The shapes of the second pair of legs 66a2 and 66a2 correspond. For example... Figure 4E As shown, a dividing piece 58 is formed in the second through hole 54. The dividing piece 58 and... Figure 5A The dividing surfaces 611a of the second set of middle legs 66a2 and 66a2 shown abut each other, dividing the dividing cores 61a and 61a along the Y-axis.
[0130] like Figure 4E As shown, a second insulating wall 56 is formed between the second main through hole 52 and the second secondary through hole 54. The second insulating wall 56 is disposed in... Figure 5A The main middle legs 64a, 64a are shown between the second secondary middle legs 66a1, 66a1, and the main middle legs are insulated from the second secondary middle legs.
[0131] like Figure 4A As shown, the second end spacer flange 32 is disposed below the second winding portion 50 in the Z-axis direction. Protrusions 32a and 32b are formed on the two outer sides of the second end spacer flange 32 relative to the center along the Y-axis.
[0132] On the inner side of the convex portions 32a and 32b along the Y-axis, conical surfaces 32a1 and 32b1 are formed, which, like the conical surfaces 12a and 12a, are inclined towards the center of the X-axis. The conical surface 32a1 is inclined towards the center of the X-axis. Figure 5A The base 62a of the shown segmented core 61a is formed in contact with the outer inclined surface 63a1 along the center of the Y-axis. The conical surface 32a2 is formed in contact with the inclined surface 63a2.
[0133] A second insertion hole 33 is formed on the second end spacer flange 32. The second insertion hole 33 and... Figure 5A The shapes of the first set of middle feet 66a1 and 66a1 are corresponding. The second insertion hole 33 is arranged to overlap with the first set of through holes 44. The first set of middle feet 66a1 is inserted into the second insertion hole 33.
[0134] like Figure 2A and Figure 2BAs shown, a first conductor 70 and a second conductor 80 are wound on the winding frame 10. The conductors 70 and 80 can be made of the same material or different materials. The outer diameter of each conductor 70 and 80 is not particularly limited, but is preferably in the range of 1.0 to 4.0 mm. Furthermore, it is preferable that an insulating film is formed on each conductor 70 and 80.
[0135] The first conductor 70 has a first coil portion 74 wound on a first winding portion 40 of the winding frame 10, and the second conductor 80 has a second coil portion 84 wound on a second winding portion 50 of the winding frame 10. For example... Figure 2C As shown, the first coil portion 74 is disposed between the first end spacer flange 30 and the winding spacer flange 34. The second coil portion 84 is disposed between the second end spacer flange 32 and the winding spacer flange 34.
[0136] like Figure 2A and Figure 2B As shown, the winding shaft O1 of the first coil section 74 is parallel to the center line O of the transformer. Figure 4A The central axes O of the first main through hole 42 and the second main through hole 52 shown are offset to one side along the X-axis. Furthermore, the winding axis O2 of the second coil section 84 is offset along the X-axis to the opposite side of the winding axis O1 of the first coil section 74 compared to the center line O. The winding axes O1 of the first coil section 74 and O2 of the second coil section 84 are aligned in the Z-axis direction.
[0137] like Figure 3 As shown, the first coil portion 74 includes a first coil outer portion 76 and a first coil inner portion 78. The first coil outer portion 76 is disposed outside the center of the X-axis relative to the center line L1 along the Y-axis via the winding shaft O1, and the first coil inner portion 78 is disposed inside the X-axis relative to the center line L1.
[0138] like Figure 2C As shown, the outer portion 76 of the first coil passes between the first outer leg 68b1 and the first secondary middle leg 66b1. Furthermore, the inner portion 78 of the first coil passes between the main middle leg 64b and the second secondary middle leg 66b2.
[0139] like Figure 6 As shown, the first conductor 70 has first lead portions 72a and 72b extending from the first coil portion 74. At each end of the first lead portions 72a and 72b, a connecting terminal 73 made of metal terminals is electrically connected, for example by soldering.
[0140] like Figure 2A As shown, the first lead portion 72a extends upward in the Z-axis direction to the first passage portion 16a. The first lead portion 72a extends outward from the center in the Y-axis direction through the first groove portion 14a1.
[0141] like Figure 2A As shown, the first lead portion 72b extends upward in the Z-axis direction to the first passage portion 16b. The first lead portion 72b extends outward from the center in the Y-axis direction through the first groove portion 14b1.
[0142] like Figure 3 As shown, the second coil portion 84 includes a second coil outer portion 86 and a second coil inner portion 88. The second coil outer portion 86 is disposed outside the center of the X-axis relative to the center line L2 along the Y-axis via the winding shaft O2, and the second coil inner portion 88 is disposed inside the X-axis relative to the center line L2.
[0143] like Figure 2C As shown, the outer portion 86 of the second coil passes between the second outer leg 68a2 and the second secondary middle leg 66a2. Furthermore, the inner portion 88 of the second coil passes between the main middle leg 64a and the first secondary middle leg 66a1.
[0144] like Figure 6 As shown, the second conductor 80 has second lead portions 82a and 82b extending from the second coil portion 84. At each end of the second lead portions 82a and 82b, a connecting terminal 83 made of metal terminals is electrically connected, for example by soldering.
[0145] like Figure 2B As shown, the second lead portions 82a and 82b extend through the cut 35 to the upper part of the second passage portion 26 in the Z-axis direction. The second lead portion 82a extends from the second passage portion 26 through... Figure 4B The first portion and the second portion of the second groove 24a1 shown extend outwards from the center in the Y-axis direction. By adopting such a structure, the second lead portion 82a is led out insulated from the first coil portion 74.
[0146] like Figure 2B As shown, the second lead portion 82b extends upward in the Z-axis direction to the second passage portion 26b. The second lead portion 82b extends outward from the center in the Y-axis direction through the second groove portion 24b1.
[0147] In this embodiment, such as Figure 2C As shown, the first coil portion 74 is wound on the first winding portion 40, and the second coil portion 84 is wound on the second winding portion 50. The first winding portion 40 and the second winding portion 50 are separated by a winding spacer flange 34 to ensure insulation between the first coil portion 74 and the second coil portion 84.
[0148] The first winding portion 40 has a first main through hole 42 for arranging the main center leg 64b and a first secondary through hole 44 for arranging the first secondary center leg 66b1. Therefore, the main center leg 64b and the first secondary center leg 66b1 are arranged inside the first coil portion 74, and the insulation between the first coil portion 74 and the core 60b is ensured.
[0149] The second winding portion 50 has a second main through hole 52 for arranging the main center leg 64a and a second auxiliary through hole 54 for arranging the second auxiliary center leg 66a2. Therefore, the main center leg 64a and the second auxiliary center leg 66a2 are arranged inside the second coil portion 84, and the insulation between the second coil portion 84 and the core 60a is ensured.
[0150] The second middle leg 66b2 of core 60b is disposed between the second outer leg 68b2 of core 60b and the inner side 78 of the first coil of the first coil portion 74. That is, the second middle leg 66b2 is disposed on the outside of the first coil portion 74. Furthermore, the first middle leg 66a1 of core 60a is disposed between the first outer leg 68a1 of core 60a and the inner side 88 of the second coil of the second coil portion 84. That is, the first middle leg 66a1 is disposed on the outside of the second coil portion 84.
[0151] By configuring the coils and the secondary neutral leg in this way, leakage flux can be generated at the secondary neutral leg even without significantly separating the coils, ensuring leakage flux and eliminating the need for a choke coil structure, thus enabling miniaturization of transformer 1. Furthermore, transformer 1 can suppress AC resistance and achieve low copper losses.
[0152] In this embodiment, such as Figure 5A As shown, core 60a can be divided into two symmetrical sub-cores 61a and 61a. Core 60b can be divided into two symmetrical sub-cores 61b and 61b. This structure allows the cores to be easily mounted onto the winding frame.
[0153] Furthermore, the dividing cores 61a and 61b are symmetrical, and each dividing core has a structure that is symmetrical about the Z-axis. Therefore, replacing the dividing cores individually will achieve the same function, thus reducing manufacturing costs.
[0154] In this embodiment, although it is Figure 3 The horizontal leakage transformer shown has its winding shaft O1 of the first coil section 74 and its winding shaft O2 of the second coil section 84 offset along the X-axis, but as... Figure 4D and Figure 4E As shown, the first winding portion 40 and the second winding portion 50 are formed into corresponding shapes of the same size. Therefore, as Figure 2CAs shown, by setting the turns ratio of the first coil section 74 to the second coil section to 1:1, their respective inductances can be easily made consistent. With such a transformer 1, switching losses can be prevented.
[0155] In this embodiment, such as Figure 2C As shown, a base 62a, positioned below the Z-axis and extending along the X-axis, and a base 62b, positioned above the Z-axis and extending along the X-axis, clamp the first coil portion 74 and the second coil portion 84. Furthermore, a first outer leg and a second outer leg, extending along the Z-axis, clamp the first coil portion 74 and the second coil portion 84 from both sides in the X-axis direction. By employing this structure, the first coil portion 74 and the second coil portion 84 can be housed between cores 60a and 60b, enabling the manufacture of a small transformer with a generally cuboid shape.
[0156] In this embodiment, such as Figure 5B As shown, a gap 100a with a distance T1 is formed between the first set of intermediate legs 66a1 and 66b1, and a gap 100b with a distance T1 is formed between the second set of intermediate legs 66a2 and 66b2. Furthermore, a gap 101 with a distance T2 is formed between the main intermediate legs 64a and 64b. Moreover, the distance T1 is longer than the distance T2. The transformer 1 can adjust leakage flux through these gaps and further prevent damage to the legs. In addition, the distance of these gaps can be changed as needed, and it functions as a leakage flux transformer even without gaps.
[0157] Furthermore, the present invention is not limited to the embodiments described above, and various modifications can be made within the scope of the present invention.
[0158] In the above-described embodiments, such as Figure 5A As shown, cores 60a and 60b are both E-type cores with five feet, or either core can be an I-type core without feet. In this case, the feet of the E-type core mate with the I-type core.
Claims
1. A coil device, in, include: Winding frame; A first conductor having a first coil portion wound around the winding frame; A second conductor having a second coil portion wound around the winding frame; and The core installed on the winding frame, The core includes: The base extending along the first axis; A main central leg disposed approximately at the center of the first axial direction of the base; A first secondary middle leg is disposed on one side of the base relative to the main middle leg in the first axial direction; and The second secondary leg is disposed on the opposite side of the first axial direction at the base. The main middle leg is disposed inside the first coil portion and the second coil portion. The first intermediate foot is positioned inside the first coil portion and outside the second coil portion. The second intermediate foot is positioned inside the second coil portion and outside the first coil portion. The winding frame has a first winding portion on which the first coil portion is wound, a second winding portion on which the second coil portion is wound, and a winding spacer flange separating the first winding portion and the second winding portion. In the first winding section, a first main through hole for arranging the main center leg and a first secondary through hole for arranging the first auxiliary center leg are formed. In the second winding section, a second main through hole for arranging the main center leg and a second secondary through hole for arranging the second auxiliary center leg are formed. The first main through hole is connected to the second main through hole. A first gap is formed in the middle foot of the first pair. A second gap is formed in the main middle foot. The distance of the first gap is longer than the distance of the second gap.
2. The coil device as claimed in claim 1, wherein, The core has a first outer leg and a second outer leg disposed on the base. The first secondary middle leg is positioned between the first outer leg and the main middle leg. The second secondary middle leg is positioned between the second outer leg and the main middle leg. The first outer leg is disposed on the outside of the first coil portion. The second outer foot is positioned on the outside of the second coil portion.
3. The coil device as claimed in claim 2, wherein, The total cross-sectional area of the main middle leg, the first outer leg, and the second outer leg is approximately the same.
4. The coil device as claimed in claim 1 or 2, wherein, The cross-sectional area of the main middle foot is greater than the cross-sectional area of the first secondary middle foot.
5. The coil device as claimed in claim 1 or 2, wherein, The core is symmetrical about an axis of symmetry orthogonal to the direction of the first axis.
6. The coil device as claimed in claim 1 or 2, wherein, The core has a first core portion and a second core portion, wherein the first core portion includes at least a first base portion that is part of the base portion; and the second core portion includes at least a second base portion that is another part of the base portion and is substantially parallel to the first base portion. The first core portion and the second core portion clamp the first coil portion and the second coil portion along the winding axis of the first coil portion.
7. The coil device as claimed in claim 6, wherein, The first core portion and the second core portion are symmetrical along the winding axis of the first coil portion.
8. The coil device as claimed in claim 1 or 2, wherein, The core is divided along a second axis perpendicular to the first axis and the winding axis of the first coil portion.