transformer

Abstract

The present invention provides a transformer comprising a plurality of cores and a winding structure. The cores are spaced apart and stacked with each other to form a plurality of core gaps between the cores, wherein relative positions between the core gaps are fixed. The winding structure is disposed outside the cores and comprises a plurality of layers of coils, wherein a position of at least one of the core gaps corresponds to a position of at least one of the layers of coils. The transformer of the present invention can have good performance.

Description

Technical Field

[0001] This invention relates to a transformer, and more particularly to a transformer with good performance. Background Technology

[0002] As the applications of transformers become increasingly diverse, improving transformer efficiency and reducing losses are the research goals of this field. Summary of the Invention

[0003] This invention provides a transformer with good performance.

[0004] The present invention discloses a transformer comprising a plurality of iron cores and a winding structure. The iron cores are stacked on top of each other at intervals, forming a plurality of core gaps, wherein the relative positions of these core gaps are fixed. The winding structure is disposed around the iron cores and comprises multiple layers of coils, wherein the position of at least one of the core gaps corresponds to the position of at least one of the layers of coils.

[0005] In one embodiment of the invention, the winding structure further includes a plurality of copper sheets or a plurality of circuit boards, which are arranged alternately with the coil, and the position of at least one of the iron core gaps is offset from the position of the copper sheets or the circuit boards.

[0006] In one embodiment of the present invention, the coils described above are high-voltage side winding groups, and the copper sheets or circuit boards are low-voltage side winding groups.

[0007] In one embodiment of the invention, the number of the aforementioned core gaps is less than or equal to the number of these layer coils.

[0008] In one embodiment of the present invention, the transformer further includes a winding frame, wherein the winding frame includes an annular sidewall and a plurality of partitions arranged in parallel within the annular sidewall, the partitions dividing the space within the annular sidewall into a plurality of first-layer frames, at least a plurality of the iron cores being inserted into these first-layer frames.

[0009] In one embodiment of the present invention, the winding frame further includes a plurality of second-layer frames, which are stacked alternately with the first-layer frames, and the core gaps are formed at least in the second-layer frames, wherein the height of the first-layer frames is greater than the height of the second-layer frames.

[0010] In one embodiment of the present invention, the winding frame further includes a third layer frame, the height of which is greater than the height of the first layer frame, and the height of the third layer frame is greater than twice the height of the iron core.

[0011] In one embodiment of the present invention, two of the aforementioned iron cores are disposed on a third layer, and a movable spacer is disposed between the two iron cores within the third layer.

[0012] In one embodiment of the invention, the winding frame includes a plurality of positioning portions extending from the inner surface of the annular sidewall and located within the first layer of the frame, the positioning portions abutting against the iron cores.

[0013] In one embodiment of the invention, the winding frame includes a separable first part and a second part, the first part including a portion of the annular sidewall and a portion of each of the partitions, and the second part including another portion of the annular sidewall and another portion of each of the partitions.

[0014] In one embodiment of the present invention, at least some of the aforementioned core gaps have the same height.

[0015] Based on the above, in the transformer of the present invention, the iron cores are stacked on top of each other at intervals, forming multiple iron core gaps between them, and the relative positions of these iron core gaps are fixed. A winding structure is disposed around the iron cores and includes multiple layers of coils, and the position of at least one of these iron core gaps corresponds to the position of at least one of these layers of coils. In the transformer of the present invention, these iron core gaps located between the iron cores can effectively reduce losses caused by edge flux effects. The fixed relative positions of these iron core gaps can effectively reduce the error between the actual and theoretical iron core gaps of the transformer. Furthermore, actual measurements show that the position of the iron core gaps corresponding to the coils can effectively reduce copper losses, thereby improving efficiency. Attached Figure Description

[0016] Figure 1 This is a perspective view of a transformer according to an embodiment of the present invention;

[0017] Figure 2 yes Figure 1 A front view diagram of the transformer coils shown in perspective;

[0018] Figure 3 yes Figure 1 A front view schematic diagram of the transformer's hidden coil;

[0019] Figure 4 This is a schematic diagram of a transformer according to another embodiment of the present invention;

[0020] Figure 5 This is a schematic diagram of a transformer according to another embodiment of the present invention;

[0021] Figure 6 This is a schematic diagram of a winding frame according to another embodiment of the present invention.

[0022] Explanation of reference numerals in the attached figures

[0023] H1, H2, H3: Height;

[0024] 100: Transformer;

[0025] 110: Iron core;

[0026] 120, 120b: Core gap;

[0027] 130: Winding structure;

[0028] 132: Coil;

[0029] 134: Copper sheet;

[0030] 140, 140b, 140c: Winding frame;

[0031] 141: Annular lateral wall;

[0032] 141c: Semi-annular lateral wall;

[0033] 142: Partition;

[0034] 142c: Half partition;

[0035] 143: First shelf;

[0036] 144: Second shelf;

[0037] 145: Third shelf;

[0038] 146: Movable spacer;

[0039] 147: Positioning section;

[0040] 148: Part One;

[0041] 149: Part Two. Detailed Implementation

[0042] 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 component reference numerals are used in the drawings and description to denote the same or similar parts.

[0043] Figure 1 This is a perspective view of a transformer according to an embodiment of the present invention. Please refer to [link / reference]. Figure 1 In this embodiment, the transformer 100 can be applied, for example, to an off-board charger for an electric vehicle (not shown), but the application of the transformer 100 is not limited to this.

[0044] Figure 2 yes Figure 1 A front view schematic diagram of the transformer coils shown in perspective. Figure 3 yes Figure 1A front view diagram of the transformer's hidden coils. Please refer to... Figures 1 to 3 In this embodiment, the transformer 100 includes multiple iron cores 110 and a winding structure 130. For example... Figure 3 As shown, these iron cores 110 are stacked on top of each other at intervals, forming a plurality of iron core gaps 120 between these iron cores 110. These iron core gaps 120 located between these iron cores 110 can effectively reduce the losses caused by edge magnetic flux effects.

[0045] In addition, such as Figure 1 As shown, a winding structure 130 is disposed around these iron cores 110 and includes multiple layers of coils 132 and multiple copper sheets 134. These copper sheets 134 are arranged alternately with these coils 132. These coils 132 are, for example, high-voltage side winding groups, and these copper sheets 134 are, for example, low-voltage side winding groups.

[0046] It is worth mentioning that, such as Figure 3 As shown, the number of these core gaps 120 is less than or equal to the number of these coils 132. In this embodiment, there are six cores 110 and five core gaps 120. Figure 1 As shown, the coil 132 has five layers, and the copper sheet 134 has four layers. In this embodiment, the number of core gaps 120 is equal to the number of coil layers 132. Of course, in other embodiments, the number of core gaps 120 may be less than the number of coils 132, and is not limited to the figures.

[0047] In addition, by Figure 2 and Figure 3 It is understood that the position of at least one of these core gaps 120 corresponds to the position of at least one of these coils 132, and the position of at least one of these core gaps 120 is offset from the position of the copper sheet 134. In this embodiment, the position of these core gaps 120 corresponds to the position of at least several of these coils 132, and the position of these core gaps 120 is offset from the position of these copper sheets 134. That is, the position of the core gaps 120 corresponds to at least a portion of the high-voltage side winding group, and is offset from at least one group of low-voltage side winding groups.

[0048] Specifically, in this embodiment, the positions of the five core gaps 120 correspond to the five coil layers 132 and are offset from the four copper sheets 134. In other words, the positions of the core gaps 120 correspond to the positions of all the coils 132. That is, the coils 132 surround the periphery of the core gaps 120 in a one-to-one manner.

[0049] Of course, in other embodiments, if the number of core gaps 120 is less than the number of coils 132, the positions of the core gaps 120 may correspond only to the positions of a portion of the coils 132. For example, in an embodiment not shown, if there are only four core gaps 120, four of the coils 132 will be wrapped around the periphery of these four core gaps 120, and the remaining coil 132 will be wrapped around the periphery of one of the cores 110.

[0050] It should be noted that in other embodiments, these copper sheets 134 may also be replaced by multiple circuit boards. That is, the low-voltage side winding assembly is formed by multiple circuit boards, and the low-voltage side winding assembly is not limited to copper sheets 134.

[0051] It is worth mentioning that in this embodiment, the positions of these iron cores 110 are fixed, which also allows the relative positions between these iron core gaps 120 to be fixed. This design can effectively reduce the error between the actual iron core gap 120 and the theoretical iron core gap of the transformer 100.

[0052] The following will further explain how transformer 100 utilizes winding frame 140 ( Figure 4 The winding structure 130 is used to fix the relative positions between these core gaps 120. It should be noted that in the following embodiments, the winding structure 130 is hidden to clearly show the relationship between the winding frame 140 and the core 110. In the following embodiments, please refer to the following for the relative positions of the winding structure 130, the core 110, and the core gaps 120. Figures 1 to 3 .

[0053] Figure 4 This is a schematic diagram of a transformer according to another embodiment of the present invention. Please refer to [link / reference]. Figure 4 The transformer 100a includes a winding frame 140. In this embodiment, the winding frame 140 includes an annular sidewall 141 (vertical wall) and a plurality of partitions 142 (horizontal plates) arranged parallel to each other within the annular sidewall 141. These partitions 142 divide the space within the annular sidewall 141 into a plurality of first shelves 143 and a plurality of second shelves 144.

[0054] In this embodiment, the first shelves 143 and the second shelves 144 are stacked alternately. The height H1 of the first shelves 143 is greater than the height H2 of the second shelves 144. The height H1 of the first shelves 143 is greater than or equal to the height of the iron core 110. Therefore, the iron cores 110 can be inserted into the first shelves 143, and the gaps 120 between the iron cores are formed at least in the second shelves 144.

[0055] In other words, in this embodiment, the first shelf 143 forms a structure similar to a drawer shelf or a rack, and the iron core 110 can be inserted into the first shelf 143, which is quite convenient to install. Since these iron cores 110 are inserted into these shelves, they are placed on the corresponding partitions 142.

[0056] Therefore, the vertical positions of these iron cores 110 are fixed. Correspondingly, the distance between these iron cores 110 is also fixed, thereby fixing the positions of the iron core gaps 120 between these iron cores 110.

[0057] Specifically, the height H2 of the core gaps 120 is contributed by the height of the second shelf 144 and the thickness of the two partitions 142. In this embodiment, the height H2 of these core gaps 120 is the same, but this is not a limitation.

[0058] Through the above design, the transformer 100a of this embodiment can fix the height H2 of the core gap 120, which can effectively reduce the error between the actual core gap 120 and the theoretical core gap of the transformer 100a, and can be manufactured in a low-cost manner.

[0059] In this embodiment, the winding frame 140 includes a plurality of positioning portions 147 extending from the inner surface of the annular sidewall 141 and located within the first layers 143. These positioning portions 147 abut against the iron cores 110. Therefore, the iron cores 110 can be abutted against by the surrounding positioning portions 147 within the first layers 143, thus maintaining the horizontal position of the iron cores 110. That is, the iron cores 110 can be securely fixed within the first layers 143. The winding frame 140 may be made of, for example, plastic. The entire winding frame 140 or the positioning portions 147 may be manufactured by 3D printing, but this is not a limitation.

[0060] Figure 5 This is a schematic diagram of a transformer according to another embodiment of the present invention. Please refer to [link / reference]. Figure 5 In this embodiment, transformer 100b and Figure 4 The main difference of transformer 100a is that, in this embodiment, the core gap 120 is contributed by the thickness of the partition 142. In addition, in addition to the first layer 143, the winding frame 140b also includes a third layer 145 in order to provide other sizes of core gap 120b to adjust the inductance.

[0061] The third layer 145 is located above the first layer 143. The height H3 of the third layer 145 is greater than the height H1 of the first layer 143, and the height H3 of the third layer 145 is greater than twice the height of the iron core 110, so that iron core gaps 120b of the same or different heights can be formed at the third layer 145.

[0062] Specifically, in this embodiment, there are six iron cores 110 and four first shelves 143. A portion of the iron cores 110 (four of them) are inserted into the first shelves 143, and two of the iron cores 110 are disposed in the third shelf 145. In addition, a movable spacer 146 is disposed between two iron cores 110 within the third shelf 145.

[0063] During assembly, one of the iron cores 110 can be placed in the third layer 145 first, and then a movable spacer 146 of the required thickness can be placed on this iron core 110. Next, the uppermost iron core 110 can be placed on the movable spacer 146. The gap 120b of the uppermost iron core is contributed by the height (thickness) of the movable spacer 146, and the height of the gap 120b of the uppermost iron core can be different from the height of the gaps 120 of the other iron cores.

[0064] Figure 6 This is a schematic diagram of a winding frame according to another embodiment of the present invention. Please refer to... Figure 6 In this embodiment, the winding frame 140c and Figure 5 The main difference between the winding frame 140b and the winding frame 140c is that, in this embodiment, the winding frame 140c includes a first part 148 (e.g., the right half) and a second part 149 (e.g., the left half) that are separable from the left and right sides. The first part 148 includes a semi-annular sidewall 141c and a semi-partition 142c. The second part 149 includes a semi-annular sidewall 141c and a semi-partition 142c.

[0065] In this embodiment, the semi-annular sidewall 141c of the first part 148 and the semi-annular sidewall 141c of the second part 149 can be assembled to form an annular sidewall 141. The semi-partition 142c of the first part 148 and the semi-partition 142c of the second part 149 can be assembled to form a partition 142.

[0066] That is, the first part 148 includes a portion of the annular sidewall 141 and a portion of each of the partitions 142, and the second part 149 includes another portion of the annular sidewall 141 and another portion of each of the partitions 142.

[0067] In this embodiment, the first portion 148 and the second portion 149 are, for example, two equally divided right and left halves. In other embodiments, the first portion 148 and the second portion 149 may also be two unequal halves, for example, the first portion 148 may be larger than the second portion 149.

[0068] The first part 148 is, for example, a fixed structure, while the second part 149 is, for example, a movable structure. During assembly, the iron cores 110 can be placed on the half-partitions 142c of the first part 148, and then the half-partitions 142c of the second part 149 can be horizontally inserted between the iron cores 110.

[0069] Similarly, in this embodiment, the winding frame 140c uses the height of the partition 142 as the core gap 120 between two adjacent cores 110. Therefore, the relative positions between these core gaps 120 can be accurately located, which can effectively reduce the error between the actual core gap and the theoretical core gap of the transformer.

[0070] In summary, the transformer of the present invention has its cores stacked at intervals, forming multiple core gaps between them, and the relative positions of these core gaps are fixed. A winding structure is disposed around the cores and includes multiple layers of coils, with the position of at least one of these core gaps corresponding to the position of at least one of these coil layers. In the transformer of the present invention, these core gaps located between the cores effectively reduce losses caused by edge flux effects. The fixed relative positions of these core gaps effectively reduce the error between the actual and theoretical core gaps of the transformer. Furthermore, actual measurements show that the position of the core gaps corresponding to the coils effectively reduces copper losses, thereby improving efficiency.

[0071] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A transformer, characterized by include: Multiple iron cores are stacked on top of each other at intervals, and multiple iron core gaps are formed between the multiple iron cores, wherein the relative positions between the multiple iron core gaps are fixed; as well as A winding structure is disposed around the plurality of iron cores and includes multiple layers of coils, wherein the position of at least one of the gaps between the plurality of iron cores corresponds to the position of at least one of the multiple layers of coils. The winding structure also includes a plurality of copper sheets or a plurality of circuit boards, which are staggered with the multiple layers of coils, and the position of at least one of the gaps between the plurality of iron cores is offset from the position of the plurality of copper sheets or the plurality of circuit boards.

2. The transformer of claim 1, wherein The multilayer coil is a high-voltage side winding group, and the plurality of copper sheets or the plurality of circuit boards are low-voltage side winding groups.

3. The transformer of claim 1, wherein The number of gaps between the multiple iron cores is less than or equal to the number of the multilayer coils.

4. The transformer of claim 1, wherein, It also includes a winding frame, wherein the winding frame includes an annular sidewall and a plurality of partitions arranged in parallel within the annular sidewall, the plurality of partitions dividing the space within the annular sidewall into a plurality of first-layer frames, and at least a plurality of the plurality of iron cores are inserted into the plurality of first-layer frames.

5. The transformer according to claim 4, characterized in that, The winding frame also includes a plurality of second-layer frames, the plurality of first-layer frames and the plurality of second-layer frames are stacked alternately, the plurality of iron core gaps are formed at least in the plurality of second-layer frames, and the height of the first-layer frames is greater than the height of the second-layer frames.

6. The transformer according to claim 4, characterized in that, The winding frame also includes a third layer frame, the height of which is greater than the height of the first layer frame, and the height of the third layer frame is greater than twice the height of the iron core.

7. The transformer of claim 6, wherein, Two of the plurality of iron cores are disposed on the third layer frame, and a movable spacer is disposed between the two iron cores within the third layer frame.

8. The transformer of claim 4, wherein, The winding frame includes multiple positioning parts that extend from the inner surface of the annular sidewall and are located within the multiple first-layer frames, and the multiple positioning parts abut against the multiple iron cores.

9. The transformer of claim 4, wherein, The winding frame includes a separable first part and a second part, the first part including a portion of the annular sidewall and a portion of each of the plurality of partitions, and the second part including another portion of the annular sidewall and another portion of each of the plurality of partitions.

10. The transformer of claim 1, wherein, At least a few of the multiple iron core gaps have the same height.

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