Transformer, power conversion device, product group of transformer, and manufacturing method of transformer

Abstract

A transformer capable of easily coping with various input voltage specifications and improving productivity is obtained. The transformer includes a core portion that forms a magnetic circuit; a primary winding and a secondary winding wound on the core portion; and a first connecting portion having a plurality of first conductive portions arranged with an insulating interval therebetween, one or both of the primary winding and the secondary winding is divided into a plurality, and each of the plurality of divided windings in the at least one divided winding has a winding portion wound on the core portion and two extension members extending from both ends of the winding portion, and the first connecting portion is connected to one of the two extension members of each of the plurality of divided windings in the at least one divided winding.

Description

Technical Field

[0001] This application relates to transformers, power conversion devices, product groups of transformers, and methods of manufacturing transformers. Background Technology

[0002] With recent environmental regulations and technological advancements surrounding automobiles, electric vehicles and hybrid vehicles are being developed and popularized across various vehicle types. Electric vehicles, like hybrid and electric vehicles, use an electric motor as their drive source and are equipped with multiple power conversion devices. These power conversion devices convert input current from direct current (DC) to alternating current (AC), from AC to DC, or convert input voltage to different voltages. Specifically, examples of power conversion devices in electric vehicles include chargers that convert commercial AC power to DC power to charge high-voltage batteries, DC / DC converters that convert DC power from high-voltage batteries to DC power of different voltages, and inverters that convert DC power from high-voltage batteries to AC power for the electric motor.

[0003] For example, a DC / DC converter is mounted on an electric vehicle to charge a low-voltage lead-acid battery from a high-voltage lithium-ion battery. To protect the surrounding environment from high voltage, the high-voltage lithium-ion battery is insulated from the chassis and the low-voltage system. In a DC / DC converter, a transformer is typically used to insulate the high-voltage input side from the low-voltage output side.

[0004] A transformer has a core forming a magnetic circuit, a primary winding, and a secondary winding, with the primary winding, for example, located on the high-voltage side. A planar transformer is disclosed (see, for example, Patent Document 1). In the planar type, the primary and secondary windings are coaxially stacked. In the case of a center-tapped transformer, the primary winding is positioned between two secondary windings. Since the primary winding has more turns than the secondary winding, starting from the terminal of the primary winding furthest from the winding axis, several turns are wound from the outer periphery to the inner periphery. The terminal closest to the winding axis is connected to the terminal of a primary winding in a different layer, and several turns are wound from the inner periphery to the outer periphery, ending at another terminal of a primary winding in a different layer. The windings of different layers are connected to each other by welding, crimping, or screw fastening.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2020-10480 Summary of the Invention

[0008] The technical problem that the invention aims to solve

[0009] With the increasing popularity of electric vehicles, electrification is being applied to various vehicle models. Depending on the vehicle model, the capacity of the high-voltage lithium-ion battery varies, resulting in different voltages. Therefore, DC / DC converters need to handle various input voltage specifications. On the other hand, regardless of the vehicle model, the voltage of the low-voltage lead-acid battery is constant, thus requiring the transformer's turns ratio to accommodate different input voltage specifications. However, the transformer structure in Patent Document 1 has a problem in easily handling various input voltage specifications. For example, if the input voltage changes, the input current also changes. Therefore, in addition to changing the number of turns, thermal design is required to ensure that the heat generated by the increased input current is manageable for the transformer. This necessitates redesigning the number of layers in the primary winding, the number of turns in each layer, the wire width, and the connection points of each layer. Furthermore, different transformers need to be manufactured for each input voltage specification. During the manufacturing process, various types of transformers must be managed, leading to complex issues related to production management and inventory management.

[0010] Therefore, the purpose of this application is to obtain a transformer, a power conversion device, a product group of transformers, and a method for manufacturing a transformer that can easily handle various input voltage specifications and improve productivity.

[0011] Technical means for solving technical problems

[0012] The transformer disclosed in this application includes: a core portion forming a magnetic circuit; a primary winding and a secondary winding wound on the core portion; and a first connection portion having a plurality of first conductive portions arranged with insulating intervals between them, one or both of the primary winding and the secondary winding being divided into a plurality of portions, each of the plurality of divided windings in at least one divided winding having a wound portion wound on the core portion and two extension members extending from both ends of the wound portion, the first connection portion being connected to one of the two extension members of each of the plurality of divided windings in at least one divided winding, in the case where the first connection portion has two first conductive portions, each of the two first conductive portions is an external connection portion connected to the outside and is an interconnection portion connecting two or more extension members to each other, in the case where the first connection portion has three or more first conductive portions, each of the two specific first conductive portions is an external connection portion, or an external connection portion and an interconnection portion, and each of one or more non-specific first conductive portions other than the two specific first conductive portions is an interconnection portion.

[0013] Invention Effects

[0014] According to the transformer disclosed in this application, one or both of the primary winding and the secondary winding are divided into multiple segments. Each of the multiple segmented windings in at least one divided winding has a wound portion wound on a core portion and two extension members extending from both ends of the wound portion. A first connecting portion is connected to one of the two extension members of each of the multiple segmented windings in at least one divided winding. When the first connecting portion has two first conductive portions, each of the two first conductive portions is an external connecting portion and an interconnecting portion that connects two or more extension members to each other. When the first connecting portion has three or more first conductive portions... Each of the two specific first conductive parts is an external connection part, or an external connection part and an interconnection part. Each of the more than one non-specific first conductive parts other than the two specific first conductive parts is an interconnection part. Therefore, the series connection and parallel connection of the split windings are switched by the connection of the extension members in the first connection part. Thus, the number of turns of the transformer can be changed while maintaining commonality without changing the core part and the winding part. Therefore, the design time when changing the number of turns and the increase in the number of transformer types due to special design can be suppressed. Various input voltage specifications can be easily handled, and a transformer with improved productivity can be obtained. Attached Figure Description

[0015] Figure 1 This is a diagram showing the circuit structure of the power conversion device according to Embodiment 1.

[0016] Figure 2 This is a table showing the voltage and the number of turns of the primary winding of the power conversion device according to Embodiment 1.

[0017] Figure 3 This is an exploded perspective view showing an outline of the main parts of the transformer involved in Embodiment 1.

[0018] Figure 4 This is an exploded perspective view showing an outline of the primary winding and the first connection portion of the transformer according to Embodiment 1.

[0019] Figure 5 This is a side view showing an outline of the windings of the transformer according to Embodiment 1.

[0020] Figure 6 This is a top view showing an outline of the first connection portion of the transformer according to Embodiment 1.

[0021] Figure 7 This is a top view showing an outline of the main parts of the transformer involved in Embodiment 1.

[0022] Figure 8This is a top view showing an outline of the primary winding and the first connection portion of the transformer according to Embodiment 1.

[0023] Figure 9 This is a side view showing an outline of the primary winding and the first connection portion of the transformer according to Embodiment 1.

[0024] Figure 10 This is a wiring structure diagram of the primary winding and the first connection part of the transformer according to Embodiment 1.

[0025] Figure 11 This is a top view showing an outline of the main parts of the transformer involved in Embodiment 1.

[0026] Figure 12 This is a diagram showing the wiring structure of the primary winding and the first connection portion of the transformer according to Embodiment 1.

[0027] Figure 13 This is a top view showing an outline of the main parts of the transformer involved in Embodiment 1.

[0028] Figure 14 This is a top view showing an outline of the primary winding and the first connection of another transformer involved in Embodiment 1.

[0029] Figure 15 This is a side view showing an outline of the primary winding and the first connection of another transformer involved in Embodiment 1.

[0030] Figure 16 This is a top view showing an outline of the primary winding and the first connection of another transformer involved in Embodiment 1.

[0031] Figure 17 This is a side view showing an outline of the primary winding and the first connection of another transformer involved in Embodiment 1.

[0032] Figure 18 This is a wiring structure diagram of the primary winding and the first connection part of another transformer involved in Embodiment 1.

[0033] Figure 19 This is a wiring structure diagram of the primary winding and the first connection part of another transformer involved in Embodiment 1.

[0034] Figure 20 This is a wiring structure diagram of the primary winding and the first connection part of another transformer involved in Embodiment 1.

[0035] Figure 21 This is a wiring structure diagram of the primary winding and the first connection part of another transformer involved in Embodiment 1.

[0036] Figure 22 This is a diagram illustrating the manufacturing process of the transformer according to Embodiment 1.

[0037] Figure 23 This is an exploded perspective view showing an outline of the primary winding, the first connection portion, and the second connection portion of the transformer according to Embodiment 2.

[0038] Figure 24 This is a top view showing an outline of the first connection portion and the second connection portion of the transformer according to Embodiment 2.

[0039] Figure 25 This is a top view showing an outline of the primary winding, the first connection portion, and the second connection portion of the transformer according to Embodiment 2.

[0040] Figure 26 This is a side view showing an outline of the primary winding and the first connection portion of the transformer according to Embodiment 2.

[0041] Figure 27 Is Figure 25 A cross-sectional view of the primary winding of a transformer cut off at section AA.

[0042] Figure 28 This is a wiring structure diagram of the primary winding, the first connection part, and the second connection part of the transformer involved in Embodiment 2.

[0043] Figure 29 This is a diagram showing the wiring structure of the primary winding, the first connection portion, and the second connection portion of the transformer according to Embodiment 2.

[0044] Figure 30 This is a diagram showing the wiring structure of the primary winding, the first connection portion, and the second connection portion of the transformer according to Embodiment 2.

[0045] Figure 31 This is a wiring structure diagram of the primary winding, the first connection part, and the second connection part of the transformer involved in Embodiment 3.

[0046] Figure 32 This is a top view showing the outline of the first connection portion and the second connection portion of the transformer according to Embodiment 3. Detailed Implementation

[0047] Hereinafter, based on the accompanying drawings, the transformer, power conversion device, transformer product group, and transformer manufacturing method involved in the embodiments of this application will be described. Furthermore, identical or equivalent components and parts will be labeled with the same reference numerals in the drawings.

[0048] Implementation method 1.

[0049] Figure 1 This is a diagram showing the circuit structure of the power conversion device 100 according to Embodiment 1. Figure 2 This is a table showing the voltage of the power conversion device 100 and the number of turns N1 of the primary winding 3a. Figure 3 This is an exploded perspective view showing the main components of transformer 3. Figure 4 This is an exploded perspective view showing the outline of the primary winding 3a and the first connection part 40a of the transformer 3. Figure 5 This is a side view showing an outline of the windings of transformer 3. Figure 6 This is a top view showing the outline of the first connection portion 40a of the transformer 3. Figure 7 This is a top view showing an outline of the main parts of transformer 3. Figure 8 This is a top view showing an outline of the primary winding 3a and the first connection portion 40a of the transformer 3. Figure 9 This is a side view showing an outline of the primary winding 3a and the first connection portion 40a of the transformer 3. Figure 10 This is a wiring diagram of the primary winding 3a and the first connection part 40a of transformer 3. Figure 11 This is a top view showing an outline of the main parts of transformer 3. Figure 12 This is a diagram showing the remaining wiring structure of the primary winding 3a and the first connection part 40a of transformer 3. Figure 13 This is a top view showing an outline of the main parts of transformer 3. The power conversion device 100 is a device that converts the DC voltage Vin of DC power supply 1 into a secondary DC voltage insulated by transformer 3 and outputs the DC voltage Vout to a load 7 such as a battery.

[0050] <Power Conversion Device 100>

[0051] use Figure 1 This example illustrates the main circuit structure of the power conversion device 100. Figure 1 In the diagram, the left side is the input side and the right side is the output side. The power conversion device 100 includes: a single-phase inverter 2 connected to a DC power supply 1 and having multiple semiconductor switching elements 2a, 2b, 2c, and 2d that convert the input DC voltage Vin into an AC voltage and output it; an insulated transformer 3 that converts and outputs the AC voltage from the single-phase inverter 2; and a rectifier circuit 4 that rectifies the output of the transformer 3. The DC power supply 1 is connected to the input side of the power conversion device 100, and a load 7, such as a low-voltage battery, is connected to the output side. A reactor 5 and a filter capacitor 6 for filtering the output are connected to the output side of the rectifier circuit 4, and the DC voltage Vout is output from the rectifier circuit 4 to the load 7 via the reactor 5 and the filter capacitor 6.

[0052] The single-phase inverter 2 has semiconductor switching elements 2a, 2b, 2c, and 2d forming a full-bridge structure. The single-phase inverter 2 is connected to the primary winding 3a of the transformer 3. The semiconductor switching elements 2a, 2b, 2c, and 2d are, for example, MOSFETs (Metal Oxide Semiconductor Field Effect Transistors) with diodes integrated between the source and drain. Alternatively, the semiconductor switching elements 2a, 2b, 2c, and 2d are not limited to MOSFETs; they can also be self-extinguishing arc-type semiconductor switching elements such as IGBTs (Insulated Gate Bipolar Transistors) with diodes connected in reverse parallel. The semiconductor switching elements 2a, 2b, 2c, and 2d are formed on a semiconductor substrate made of semiconductor materials such as silicon (Si), silicon carbide (SiC), or gallium nitride (GaN).

[0053] The rectifier circuit 4 has semiconductor elements, namely diodes 4a and 4b, which serve as rectifier elements. The transformer 3 has a primary winding 3a and secondary windings 3b and 3c. The secondary side of the transformer 3 is center-tapped, and the center-tapped terminal is connected to GND. The terminals on the secondary side other than the center-tapped terminal are connected to the anode terminals of diodes 4a and 4b, respectively. The cathode terminals of diodes 4a and 4b are connected to reactor 5. The rectifier circuit 4 rectifies the low-voltage AC power output from the secondary windings 3b and 3c and converts it into a DC pulse voltage. The reactor 5 and the filter capacitor 6 filter the DC pulse voltage.

[0054] As an example of the power conversion device 100, an example of a DC / DC converter with a center-tapped secondary side has been shown, but the secondary side can also be a full-bridge structure. Additionally, an example of a DC / DC converter with a full-bridge primary side has been shown; however, other types can also be used, as long as they are insulated converters with insulated transformers such as forward, flyback, or LLC types.

[0055] <Winding ratio and heat generation of transformer 3>

[0056] Next, taking the case of a change in input voltage specifications as an example, we will explain why the winding ratio of transformer 3 needs to be changed according to the input and output voltage specifications. When the number of turns of the primary winding 3a of transformer 3 is N1 and the number of turns of the secondary windings 3b and 3c is N2, the turns ratio N is expressed by equation (1).

[0057] [Mathematical Expression 1]

[0058]

[0059] When the input voltage is Vin, the output voltage is Vout, and the duty cycle of semiconductor switching elements 2a, 2b, 2c, and 2d is D, the turns ratio is expressed by equation (2).

[0060] [Mathematical Expression 2]

[0061]

[0062] In equation (2), the turns ratio N and duty cycle D have degrees of freedom for selection. Generally speaking, when the output voltage and output current of the load 7 output to the DC / DC converter are constant, the smaller the duty cycle D and the larger the turns ratio N, the more the peak value and effective value of the rectangular current waveform of the semiconductor switching elements 2a, 2b, 2c, 2d and the primary winding 3a of the transformer 3 increase. Therefore, in order to suppress the losses of the DC / DC converter, the duty cycle D is generally set to the maximum achievable value, and the turns ratio N of the transformer 3 is set to a smaller value.

[0063] according to Figure 2 Here's an example illustrating the specific required turns ratio N. For simplicity, the power conversion device 100 is a step-down DC / DC converter, and the turns ratio of the secondary windings 3b and 3c is set to N2 = 1. The first input / output voltage is specified as an input voltage of 100V to 200V and an output voltage of 14V, and the second input / output voltage is specified as an input voltage of 200V to 300V and an output voltage of 14V. Furthermore, the single-phase inverter 2 alternates between periods when semiconductor switching elements 2a and 2d are turned on and semiconductor switching elements 2b and 2c are turned off, and periods when semiconductor switching elements 2a and 2d are turned off and semiconductor switching elements 2b and 2c are turned on. However, to prevent bridge arm short circuits, a dead time period for turning off all semiconductor switching elements 2a, 2b, 2c, and 2d must be provided. Therefore, it is assumed that the maximum achievable duty cycle D is 0.9. Additionally, the turns ratio N needs to be set to output the determined output voltage at the minimum value of the input voltage range. Under the above conditions, when using equation (2) to calculate the number of primary turns N1 of the primary winding 3a of transformer 3, as follows: Figure 2 As shown, for the first input / output voltage specification, the primary winding N1 requires 6 turns, while for the second input / output voltage specification, it requires 12 turns. In other words, the primary winding N1 needs to be changed depending on the range of the input voltage specifications. Furthermore, in the primary winding 3a with a larger number of turns, the current decreases.

[0064] Next, we will explain the effect of the change in current magnitude on transformer 3 due to the different input voltage specifications. When the effective value of the input current from DC power supply 1 to DC / DC converter is set as Iin and the output current from DC / DC converter to load 7 is set as Iout, the effective value of the input current is represented by equation (3).

[0065] [Mathematical Expression 3]

[0066]

[0067] For simplicity, the efficiency of the DC / DC converter is set to 1. If the output power (=Vout×Iout) is constant, the input current increases inversely when the input voltage decreases. Within the range of the input voltage specifications, the input current is the largest when the input voltage is the lowest. Therefore, the lower limit of the input voltage range is 100V for the first input / output voltage specification and 200V for the second input / output voltage specification. According to equation (3), the input current for the first input / output voltage specification is twice that for the second input / output voltage specification. Therefore, when the transformer 3 changes from the second input / output voltage specification to the first input / output voltage specification, if the number of primary turns N1 is changed from 12 turns to 6 turns, the current flowing through the primary winding 3a becomes twice. Therefore, the winding loss caused by the doubled current requires a change in the winding cross-sectional area of ​​the primary winding 3a so that the heat generated by the primary winding 3a of the transformer 3 is within the range required for the transformer to function. In other words, depending on the range of the input voltage specifications, it is necessary not only to change the number of primary turns N1, but also to design for the increase in current of the primary winding 3a caused by the change in the number of primary turns N1.

[0068] <Structure of Transformer 3>

[0069] The structure of transformer 3 is described below. Transformer 3 includes: a core portion forming a magnetic circuit; a primary winding 3a and secondary windings 3b and 3c wound on the core portion; and a first connection portion 40a having a plurality of first conductive portions arranged with insulating intervals between them. Part or all of the primary winding 3a and the secondary windings 3b and 3c are sealed by a resin member 301. The portion sealed by the resin member 301 is... Figure 3The winding body 300 is shown. The insulation performance of each winding is ensured by covering the portions between and around each winding with resin member 301. A portion of the external connection portion and a portion of the interconnection portion of the first connection portion 40a connected to the primary winding 3a are exposed from the resin member 301. The first connection portion 40a is connected to the single-phase inverter 2 in the exposed portion of the external connection portion. Details of the first connection portion 40a will be described later. The portions connecting to the outside of the secondary windings 3b and 3c are also exposed from the resin member 301. The secondary windings 3b and 3c are connected to the rectifier circuit 4 in the portions connected to the outside. Figure 5 As shown, the transformer 3 includes a cooler 302 thermally connected to the resin component 301. The cooler 302 releases the heat generated when current flows through the transformer 3 to the outside. The resin component 301 has an exposed portion 301a formed by a portion of one or both of the primary winding 3a and the secondary windings 3b and 3c being exposed to the side of the cooler 302. Figure 5 Only a portion of the exposed portion 301a is shown. One or both of the primary winding 3a and the secondary windings 3b and 3c are thermally connected to the cooler 302 at the exposed portion 301a via an insulating heat-conducting member 303.

[0070] The core portion has an annular outer core and a columnar central core, i.e., a winding shaft 103, connecting two opposing parts within the outer core. The primary winding 3a and secondary windings 3b and 3c are wound on the winding shaft 103. This configuration allows for efficient winding of the primary winding 3a and secondary windings 3b and 3c onto the core portion, which has a closed magnetic circuit structure. The core portion is made of a magnetic material such as ferrite. In this embodiment, as... Figure 3 As shown, the core portion has a lower core 101 and an upper core 102. By overlapping the lower core 101 and upper core 102, which are formed in an E-shape, a core portion with a closed magnetic circuit structure is formed. The structure of the core portion is not limited to the lower core 101 and upper core 102 formed in an E-shape; it can also be two segmented cores formed in an E-shape and an I-shape. Furthermore, the mating surface between the lower core 101 and the upper core 102 is rectangular, but the shape of the mating surface can also be other shapes such as squares or circles. In this embodiment, as... Figure 4 The diagram shows an example of a planar transformer 3 formed by stacked windings made of sheet metal, but the structure shown in this application is not limited to planar transformers.

[0071] One or both of the primary winding 3a and the secondary windings 3b and 3c are divided into multiple segments, and each of the multiple segmented windings in the at least one divided winding has a winding portion wound on a core portion and two extension members extending from both ends of the winding portion. A first connecting portion 40a is connected to one of the two extension members of each of the multiple segmented windings in the at least one divided winding. The number of turns on the transformer of the at least one divided winding is set by the first connecting portion 40a through a portion separated by an insulation gap and an interconnecting portion connecting two or more extension members to each other. With this configuration, the number of turns on the transformer is set in the first connecting portion 40a without changing the structure of the primary winding 3a and the secondary windings 3b and 3c. Therefore, various input voltage specifications can be easily accommodated, and a transformer 3 with improved productivity can be easily obtained. In this embodiment, the primary winding 3a is a plurality of segmented windings in the at least one divided winding. The other of the two extension members of each of the multiple segmented windings is interconnected. The structure of the primary winding 3a will be described in detail below.

[0072] <Structure of primary winding 3a>

[0073] First, an example of a primary winding 3a is shown, in which the number of turns N2 of the secondary windings 3b and 3c is set to N2 = 1, and the number of turns N1 of the primary winding 3a is set to N1 = 6 or N1 = 12. The example of the primary winding 3a is shown. Figure 4 The single-dotted line in the diagram indicates the winding axis 103a, showing the direction in which the winding shaft 103 extends. In this application's description, the direction in which the winding axis 103a extends is defined as the z-direction, and the two directions orthogonal to and mutually orthogonal to the z-direction are defined as the x-direction and the y-direction. In this embodiment, among the primary winding 3a and the secondary windings 3b and 3c, the winding with a larger number of turns is one of multiple segmented windings in at least one segmented winding. As described above, by providing the first connection portion 40a on the winding with a larger number of turns to change the structure of the number of turns, a connection pattern with more extension members can be constructed. Furthermore, for the number of turns in the other winding, the turns ratio required for a transformer can be easily adjusted.

[0074] The primary winding 3a and the secondary windings 3b and 3c are formed by multiple winding components. Each of the multiple winding components is formed as a curved plate on the same plane orthogonal to the extension direction of the portion of the core on which the winding is wound, i.e., the winding shaft 103. The plate surface is orthogonal to the extension direction of the winding shaft 103, and the multiple winding components are stacked in the extension direction of the winding shaft 103. Figure 4 The winding components of the primary winding 3a shown are segmented windings, for example, made of copper. Figure 4The winding portion in each winding component of the primary winding 3a shown is a vortex shape with a portion bent at a right angle, but the shape of the winding portion is not limited to this, and can also be circular or elliptical.

[0075] In this embodiment, the winding member of the primary winding 3a is from Figure 4 The Z-axis negative direction side is sequentially stacked to form the first primary winding 201, the second primary winding 202, the third primary winding 203, and the fourth primary winding 204. Resin component 301 for insulation ( Figure 4 (Not shown in the diagram) It is inserted between the windings. For example, as... Figure 5 As shown, the secondary winding 3c is stacked between the first primary winding 201 and the second primary winding 202, and the secondary winding 3b is stacked between the third primary winding 203 and the fourth primary winding 204. This configuration improves the electromagnetic coupling between the primary and secondary windings and reduces leakage inductance. The stacked structure of the primary winding 3a and the secondary windings 3b and 3c is not limited to this. The contours of the primary winding 3a and the secondary windings 3b and 3c are aligned in the x and y directions, respectively. For each of the winding members of the primary winding 3a, which is a dividing winding, one of the two extension members extends from the end furthest from the winding shaft 103, and the other of the two extension members extends from the end closest to the winding shaft 103.

[0076] The plurality of winding members have at least one first winding member and at least one second winding member. Viewed from the extending direction of the winding shaft 103, the first winding member has a winding portion wound clockwise on the winding shaft 103 from a side away from the winding shaft 103 toward a side closer to the winding shaft 103. The second winding member has a winding portion wound counterclockwise on the winding shaft 103 from a side away from the winding shaft 103 toward a side closer to the winding shaft 103. In this embodiment, the first primary winding 201 and the third primary winding 203 are first winding members, and the second primary winding 202 and the fourth primary winding 204 are second winding members. In the wiring diagram, the first winding member is labeled as a reverse winding, and the second winding member is labeled as a forward winding.

[0077] The winding unit is formed by a first winding member and a second winding member. The ends of the first winding member and the second winding member in the winding unit near the winding shaft 103 are connected to each other, and each extension member extends from the end away from the winding shaft 103. In this embodiment, the winding unit 30 is formed by a first primary winding 201 and a second primary winding 202, and the winding unit 31 is formed by a third primary winding 203 and a fourth primary winding 204.

[0078] The first primary winding 201 is wound 3 turns on the winding shaft 103. The winding end 2011, which is an extension member near the winding shaft 103, has a bent structure that bends towards the second primary winding 202. The second primary winding 202 is wound 3 turns on the winding shaft 103. The winding end 2021, which is an extension member near the winding shaft 103, has a bent structure that bends towards the first primary winding 201. The bent structure may be present in either the winding ends 2011 or 2021 while the other is absent. In this embodiment, as... Figure 9 As shown, only the winding end 2011 has a bent structure. The winding end 2011 and the winding end 2021 are connected in series, for example, by welding, to form a winding unit 30.

[0079] The third primary winding 203 is wound 3 turns on the winding shaft 103. The winding end 2031, which is an extension member near the winding shaft 103, has a bent structure that bends towards the fourth primary winding 204. The fourth primary winding 204 is wound 3 turns on the winding shaft 103. The winding end 2041, which is an extension member near the winding shaft 103, has a bent structure that bends towards the third primary winding 203. The bent structure may be present in either the winding ends 2031 or 2041 while the other is absent. In this embodiment, as... Figure 9 As shown, only the winding end 2031 has a bent structure. The winding end 2031 and the winding end 2041 are connected in series, for example, by welding, to form a winding unit 31.

[0080] like Figure 4 As shown, the transformer 3 has multiple winding units 30 and 31. The winding directions of the multiple winding units 30 and 31 are the same. In this embodiment, each of the winding units 30 and 31 has the same number of turns, which is 6 turns. The number of turns of each of the winding units 30 and 31 is not limited to being the same, and the number of turns can also be different. The extension members on the side away from the winding axis 103 of the first primary winding 201, the second primary winding 202, the third primary winding 203, and the fourth primary winding 204 are winding ends 2012, 2022, 2032, and 2042. The first connecting part 40a connects the winding ends 2012, 2022, 2032, and 2042 of the multiple winding units 30 and 31 in series or in parallel. When the winding ends 2012, 2022, 2032, and 2042 of the winding units 30 and 31 are connected in series at the first connecting part 40a, the transformer 3 has 12 turns. When the extension members of winding units 30 and 31 are connected in parallel at the first connection part 40a, the transformer 3 has 6 turns. Thus, the number of turns on the transformer is set at the first connection part 40a.

[0081] <First connecting part 40a>

[0082] The first connecting part 40a, which is a major part of this application, is described. Figure 4 The portion surrounded by the dotted line, namely the first connecting portion 40a, is made of a plate-shaped metal such as copper. The first connecting portion 40a is integrated with one of the two extension members of each of the plurality of segmented windings in at least one of the divided windings. In this embodiment, the first connecting portion 40a is integrated with the winding end 2042 of the fourth primary winding 204, which serves as an extension member. When the winding end 2042 of the fourth primary winding 204, which serves as an extension member, and the first connecting portion 40a are integrated, the productivity of the transformer 3 can be improved because the process of connecting the winding end 2042 and the first connecting portion 40a is not required. The segmented winding integrated with the first connecting portion 40a is not limited to the fourth primary winding 204, but can also be other primary windings. In addition, the first connecting portion 40a is not limited to the structure integrated with the segmented winding, and can also be provided separately from the segmented winding.

[0083] like Figure 6 As shown, the first connecting portion 40a has: through holes 41, 42, and 43 respectively connected to the ends of the windings; interconnecting portions 411, 421, and 431 connecting the ends of the windings to each other; and external connecting portions 4111 and 4211 connected to the outside. Figure 7 As shown, portions of the external connecting portions 4111 and 4211, and portions of the interconnecting portions 411, 421, and 431 are exposed from the resin member 301. A portion of the interconnecting portions 411, 421, and 431 is a portion that is cut off to form an insulating space. A portion of any one of the interconnecting portions 411, 421, and 431 is disconnected, forming a plurality of first conductive portions arranged with insulating spaces between each other from the first connecting portion 40a. Because portions of the interconnecting portions 411, 421, and 431 are exposed from the resin member 301, portions of the interconnecting portions 411, 421, and 431 can be easily cut off. The interconnecting portions 411, 421, and 431 are not limited to a structure where only a portion is exposed from the resin member 301; all interconnecting portions 411, 421, and 431 may also be exposed from the resin member 301. Figure 11 , Figure 13 The diagram shows a structure in which a portion of any one of the interconnecting portions 411, 421, and 431 is cut off. Figure 11 Three first conductive parts were formed in the middle. Figure 13 Two first conductive portions are formed in the middle. Since a portion of the external connecting portions 4111 and 4211 is exposed from the resin member 301, the external connecting portions 4111 and 4211 can be easily connected to the outside.

[0084] like Figure 8As shown, winding end 2022 is connected to through hole 41, winding end 2032 is connected to through hole 42, and winding end 2012 is connected to through hole 43. Winding ends 2012, 2022, and 2032 pass through through holes 43, 41, and 42 respectively, for example, by solder (not shown). Figure 4 As shown, the winding ends 2012, 2022, and 2032 have bending structures 2013, 2023, and 2033 that bend in the Z direction for connection to the first connection portion 40a. Since the winding ends are connected at the through hole, the connection structure at the first connection portion 40a is simplified, thereby improving the productivity of the transformer 3.

[0085] Viewed along the extending direction of the winding shaft 103, the segmented winding having an extension member integrated with the first connecting portion 40a is arranged on the outermost side among the stacked winding members. In this embodiment, the fourth primary winding 204 having a winding end 2042 integrated with the first connecting portion 40a is arranged on the outermost side when viewed along the extending direction of the winding shaft 103. With this configuration, the bending directions of the bending structures 2013, 2023, and 2033 can be unified, thus allowing easy connection of the winding ends 2012, 2022, and 2032 to the first connecting portion 40a from one direction. Alternatively, the winding end integrated with the first connecting portion 40a can be the winding end 2012. In this case, the first primary winding 201 having the winding end 2012 is arranged on the outermost side when viewed along the extending direction of the winding shaft 103.

[0086] This describes the case where the first connecting portion 40a connects the winding ends 2012, 2022, 2032, and 2042 of the winding units 30 and 31 in series to form 12 turns. When forming 12 turns, portions of the interconnecting portions 411 and 431 are removed, for example, by a tie rod cutting process. The interconnecting portions 411 and 431 become insulating spacers 451 and 471, thereby... Figure 11 As shown, three first conductive portions are formed. These three first conductive portions are formed by cutting at insulation intervals 451 and 471. When insulation intervals 451 and 471 are cut to form multiple first conductive portions, multiple first conductive portions can be easily formed. Because multiple first conductive portions can be easily formed, the productivity of transformer 3 can be improved.

[0087] When the first connection portion 40a has three or more first conductive portions, each of the two specific first conductive portions is an external connection portion, or an external connection portion and an interconnection portion, and one or more non-specific first conductive portions other than the two specific first conductive portions are interconnection portions. In this embodiment, in Figure 11In the middle, the first conductive portions on both sides are two specific first conductive portions, which are external connection portions 4111 and 4211. The central first conductive portion is a non-specific first conductive portion, which is the interconnection portion 421. For example... Figure 10 As shown, since winding unit 30 and winding unit 31 are connected in series in interconnection part 421, a transformer 3 with a primary number of turns N1 = 12 turns can be realized.

[0088] This describes the case where the first connecting portion 40a connects the winding ends 2012, 2022, 2032, and 2042 of the winding units 30 and 31 in parallel to form 6 turns. When 6 turns are formed, for example, a portion of the interconnecting portion 421 is removed by tie rod cutting. The interconnecting portion 421 becomes an insulating space 461, thereby... Figure 13 As shown, two first conductive portions are formed. The two first conductive portions are formed by cutting at the insulating interval 461.

[0089] When the first connecting portion 40a has two first conductive portions, each of the two first conductive portions is an external connecting portion connected to the outside, and is an interconnecting portion that connects two or more extension members to each other. In this embodiment, in Figure 13 In the diagram, the two first conductive parts are external connection parts 4111 and 4211, and interconnect parts 411 and 431. For example... Figure 12 As shown, since winding unit 30 and winding unit 31 are connected in parallel in interconnection parts 411 and 431, a transformer 3 with a primary number of turns N1 = 6 turns can be realized.

[0090] Compared to a transformer 3 with 12 turns in its primary winding 3a (N1 = 6 turns), a transformer 3 with 6 turns in its primary winding 3a experiences twice the current flowing through it because the number of turns in the primary winding 3a is halved. However, since the primary winding 3a is achieved through the parallel connection of winding units 30 and 31, the current flowing through each of the first primary winding 201, the second primary winding 202, the third primary winding 203, and the fourth primary winding 204 is the same as when the number of turns N1 is 12. That is, even if the current flowing through the primary side of the transformer 3 changes due to the change in the number of turns N1, since the current flowing through each of the first primary winding 201, the second primary winding 202, the third primary winding 203, and the fourth primary winding 204 is the same, there is no need to redesign the winding width or reconsider the cooling method to keep the heat generation of the primary winding 3a within the range required for a transformer. This is particularly effective when the cooling conditions of the first primary winding 201, the second primary winding 202, the third primary winding 203, and the fourth primary winding 204 are roughly the same, for example, natural heat dissipation, or cooling from the two surfaces of the first primary winding 201 and the fourth primary winding 204, which are the outermost layers of the primary winding 3a.

[0091] As described above, by switching the series and parallel connections of winding units 30 and 31 in the first connection portion 40a, which has multiple first conductive portions arranged with insulating intervals between each other, the number of turns N1 of the primary winding 3a can be switched to 6 turns and 12 turns while maintaining commonality and without changing the core portion and the winding portion of the segmented winding of the transformer 3. Therefore, since various input voltage specifications can be easily accommodated, it is not necessary to redesign the core portion and winding components of the transformer 3, thus allowing for the commonality of the types of materials constituting the transformer 3. Because the types of materials constituting the transformer 3 are common, the design time for changing the number of turns and the increase in the types of transformers 3 due to dedicated designs can be suppressed, making production management and inventory management during the manufacture of the transformer 3 easier, thereby improving the productivity of the transformer 3. Since the switching between the series and parallel connections of winding units 30 and 31 can be performed in the first connection portion 40a, it is not necessary to prepare and replace dedicated components corresponding to each connection for changing the connection, making production management and inventory management during manufacturing easier.

[0092] By using the transformer 3 shown in this embodiment in the power conversion device 100, various input voltage specifications can be easily accommodated, thereby obtaining a power conversion device 100 with improved productivity. In this embodiment, the transformer 3 is assumed to be a planar transformer. Since the transformer 3 is a planar transformer, it is easy to stack and arrange segmented windings. By stacking the segmented windings in the extension direction of the winding shaft 103, multiple extension members can be included, thus enabling more connection patterns in the first connection portion 40a. In addition, by stacking, especially by centrally arranging the extension members close to the winding shaft 103, it is easy to connect the extension members to each other or to the first connection portion 40a. Furthermore, by changing the position of the extension members, non-integer numbers of turns (e.g., 2.5 turns or 3.5 turns) can be easily configured. Furthermore, the projected area of ​​the transformer 3 can be reduced.

[0093] <Modified example of the first connecting part 40a>

[0094] Although Figure 4 An example is shown where the first connection portion 40a is integrated with the winding end 2042, but the first connection portion 40a is not limited to a structure integrated with the segmented winding. A modified example of the first connection portion 40a, in which it is provided separately from the segmented winding, will be described. Figure 14 This is a top view showing an outline of the primary winding 3a and the first connection portion 40a of the other transformer 3 involved in Embodiment 1. Figure 15 This is a side view showing an outline of the primary winding 3a and the first connection portion 40a of the other transformer 3. Figure 16 This is a top view showing an outline of the primary winding 3a and the first connection portion 40a of another transformer 3 according to Embodiment 1. Figure 17 This is a side view showing an outline of the primary winding 3a and the first connection 40a of another transformer 3.

[0095] Both of the first connecting parts 40a are made of plate-shaped metals such as copper. Figure 14 and Figure 15 The first connecting part 40a shown is arranged parallel to the xy plane. Figure 16 and Figure 17 The first connecting portion 40a shown is arranged parallel to the yz plane. Each of the first connecting portions 40a has four through holes 41, 42, 43, and 44. (As shown...) Figure 14 As shown, winding end 2022 is connected to through hole 41, winding end 2032 is connected to through hole 42, winding end 2012 is connected to through hole 43, and winding end 2042 is connected to through hole 44. Figure 17As shown, winding end 2022 is connected to through hole 41, winding end 2032 is connected to through hole 42, winding end 2012 is connected to through hole 43, and winding end 2042 is connected to through hole 44.

[0096] Even if the split winding and the first connection portion 40a are provided separately, various input voltage specifications can be easily accommodated as in the previously shown example, resulting in a transformer 3 with improved productivity. Furthermore, when the first connection portion 40a is provided separately, the configuration freedom of the first connection portion 40a can be increased. Additionally, the split winding and the first connection portion 40a can be made of different materials. When the first connection portion 40a is formed of a material with higher thermal conductivity than the split winding, the first connection portion 40a is thermally connected to the cooler of the power conversion device via a heat sink, thereby suppressing the heat generation of the first connection portion 40a.

[0097] <Example of a modified structure for primary winding 3a>

[0098] This section describes a variation of the structure of the primary winding 3a. Figure 18 This is a wiring diagram of the primary winding 3a and the first connection portion 40a of the other transformer 3 involved in Embodiment 1. Figure 19 This is a diagram showing the wiring structure of the primary winding 3a and the first connection part 40a of the other transformer 3. Figure 20 This is a wiring diagram of the primary winding 3a and the first connection portion 40a of another transformer 3 involved in Embodiment 1. Figure 21 This is a different wiring diagram of the primary winding 3a and the first connection part 40a of another transformer 3. In the modified example, the transformer 3 has a different number of turns in its primary winding 3a. Figure 10 and Figure 12 The structure. In the modified example, except for the number of turns of the primary winding 3a, the configuration structure of the primary winding 3a is the same as... Figure 4 same.

[0099] exist Figure 10 and Figure 12 The wiring structure shown illustrates examples of changing the number of turns in primary winding 3a to 6 and 12 turns. The number of turns in each segment of primary winding 3a can be changed by setting it to 3 turns; it is not necessary to set the number of turns in primary winding 3a to a multiple of 3. For example... Figure 18 and Figure 19 As shown, the number of turns of the primary winding 3a can also be set to, for example, 5 or 10 turns.

[0100] The first primary winding 205 has two turns wound on the winding shaft 103. The winding end 2051, serving as an extension member near the winding shaft 103, has a bent structure that bends towards the second primary winding 202. The second primary winding 202 has three turns wound on the winding shaft 103. The winding end 2021, serving as an extension member near the winding shaft 103, has a bent structure that bends towards the first primary winding 205. The bent structure may be present in either winding end 2051 or 2021 while the other is absent. The winding ends 2051 and 2021 are connected in series, for example, by welding, to form a winding unit 32.

[0101] The third primary winding 206 is wound with two turns on the winding shaft 103. The winding end 2061, serving as an extension member near the winding shaft 103, has a bent structure that bends towards the fourth primary winding 204. The fourth primary winding 204 is wound with three turns on the winding shaft 103. The winding end 2041, serving as an extension member near the winding shaft 103, has a bent structure that bends towards the third primary winding 206. The bent structure may be present in either winding end 2061 or 2041 while the other is absent. The winding ends 2061 and 2041 are connected in series, for example, by welding, to form a winding unit 33.

[0102] The number of turns and the winding direction of winding units 32 and 33 are the same. In the modified example, each of winding units 32 and 33 has 5 turns. The extension members on the side away from the winding axis 103 of the first primary winding 205, the second primary winding 202, the third primary winding 206, and the fourth primary winding 204 are winding ends 2052, 2022, 2062, and 2042. The first connecting part 40a connects the winding ends 2052, 2022, 2062, and 2042 of winding units 32 and 33 in series or in parallel.

[0103] For example, by removing portions of the interconnecting parts 411 and 431 of the first connecting portion 40a through a tie rod cutting process, the interconnecting parts 411 and 431 become insulating spacers 451 and 471. With the insulating spacers 451 and 471 formed, the first connecting portion 40a is connected in series with the winding ends 2052, 2022, 2062, and 2042 of the winding units 32 and 33, thereby achieving... Figure 18 As shown, transformer 3 has 10 turns. For example, by removing part of the interconnecting portion 421 of the first connection portion 40a through tie rod cutting, the interconnecting portion 421 becomes an insulating space 461. With the insulating space 461 formed, the winding ends of the winding units 32 and 33 are connected in series by the first connection portion 40a, thereby... Figure 19 As shown, transformer 3 has 5 turns.

[0104] The structure of the primary winding 3a with 5 or 10 turns is not limited to Figure 18 and Figure 19 The structure. For example... Figure 20 and Figure 21 As shown, even if each of the segmented windings of the primary winding 3a has 2.5 turns, the winding units 32 and 33 can be connected in series or in parallel through the first connecting part 40a, so that the number of turns of the primary winding 3a can be 5 or 10.

[0105] The winding portions of the first primary winding 205 and the third primary winding 206 have gaps between each turn to increase the winding width, so that their shape overlaps with the second primary winding 202 and the fourth primary winding 204 when viewed from the extension direction of the central core. With this configuration, when each of the winding units 32 and 33 has 5 turns, compared to when each of the winding units 30 and 31 has 6 turns, the increase in primary winding losses 3a due to the increase in primary side current can be suppressed.

[0106] In the first primary winding 205 and the third primary winding 206, the winding ends 2051, 2061, 2052, and 2062, which are portions other than the winding portion, and the portion of the extension member are configured to be consistent with... Figure 4 The first primary winding 201 and the third primary winding 203 shown are partially identical. Therefore, the number of turns can be changed simply by changing the winding components without altering the shape and connection of the transformer 3. In this example, an example of changing from 3 turns to 2 turns is shown; however, except for the winding portion, winding components with more than 1 turn of the same structure can be prepared, and the winding components can be selected to accommodate any number of primary turns N1.

[0107] <Product Group 3 of Transformer>

[0108] This describes a transformer product group comprising multiple types of transformers 3. Each of the multiple types of transformers 3 includes: a core portion forming a magnetic circuit; a primary winding and a secondary winding wound on the core portion; and a first connection portion having multiple first conductive portions arranged with insulating intervals between them. One or both of the primary winding and the secondary winding are divided into multiple portions, and each of the multiple divided windings in at least one of the divided windings has a wound portion wound on the core portion and two extension members extending from both ends of the wound portion.

[0109] The first connection portion is connected to one of the two extension members of each of the plurality of segmented windings in at least one of the divided windings. The portion of the first connection portion connected to one of the two extension members of each of the plurality of segmented windings is designated as the connected portion. The plurality of connected portions are arranged with spacing intervals. Insulation intervals are provided in the spacing intervals. The spacing intervals with insulation intervals differ between different models of transformer 3, and the first conductive portion exists in the spacing intervals without insulation intervals. With this configuration, transformer 3 models with different connection structures in the first connection portion can be easily managed as a product group. Since production management and inventory management during the manufacture of transformer 3 become easier, the productivity of transformer 3 can be improved.

[0110] An example of the mechanism structure in the first connecting part is explained. In the case where the first connecting part has two first conductive portions, each of the two first conductive portions is an external connecting portion connected to the outside, and is an interconnecting portion connecting two or more extension members. This mechanism structure is, for example,... Figure 13 The structure shown depicts a transformer 3 in which winding units 30 and 31 are connected in parallel. In cases where the first connection portion has three or more first conductive portions, each of two specific first conductive portions is an external connection portion, or an external connection portion and an interconnection portion; each of one or more non-specific first conductive portions, in addition to the two specific first conductive portions, is an interconnection portion. This type of structure is, for example,... Figure 11 The structure shown allows for the parallel connection of winding units 30 and 31 in the transformer 3 of a particular model. This configuration makes it easy to manage multiple transformers 3 of different models, with winding units 30 and 31 connected in parallel or series, as a product group.

[0111] <Manufacturing Method of Transformer 3>

[0112] Regarding the manufacturing method of transformer 3, using Figure 22 Let me explain. Figure 22 This diagram illustrates the manufacturing process of transformer 3. Transformer 3 is manufactured in three steps: component preparation (S11), winding (S12), connection (S13), and cutting (S14). The component preparation step involves preparing the lower core 101 and upper core 102, the primary winding and secondary winding, and the first connecting member that forms the first connecting part 40a, which are the core portion forming the magnetic circuit. The winding step involves winding the primary and secondary windings onto the core portion. The connection step involves connecting one or both of the primary and secondary windings to the first connecting member. The cutting step involves cutting the first connecting member. A detailed explanation follows.

[0113] In the component preparation process, one or both of the primary and secondary windings are divided into multiple parts, and each of the multiple divided windings in at least one of the divided windings has a wound portion wound on the core and two extension members extending from both ends of the wound portion. When the transformer 3 is a planar transformer, the winding process is the process of arranging the winding members of the primary and secondary windings on the core.

[0114] In the connecting process, one side of each of the two extension members of each of the plurality of segmented windings in at least one segmented winding is connected to the first connecting member across a configuration interval. In the cutting process, depending on the type of transformer, portions of different configuration intervals are cut within the plurality of configuration intervals. By manufacturing the transformer 3 in this way, the type of transformer can be easily changed by cutting different configuration intervals in the first connecting member during the cutting process, thus enabling the easy manufacture of transformers 3 of multiple types. Since multiple types of transformers 3 can be easily manufactured, the productivity of transformers 3 of multiple types can be improved.

[0115] Based on the transformer model, an example of a model change based on a cutting process that alters the cutting point is described. In the case where the first connecting member is cut into two to form two conductive portions, each of the two conductive portions is an external connecting portion connected to the outside, and two or more extending members are cut into interconnecting portions. This model structure is, for example, as follows: Figure 13 The structure shown depicts a transformer 3 in which winding units 30 and 31 are connected in parallel. When the first connecting member is cut into three or more parts to form three or more conductive portions, each of the two specific conductive portions is an external connecting portion, or an external connecting portion that also becomes an interconnecting portion, and each of the one or more non-specific conductive portions other than the two specific conductive portions is cut into interconnecting portions. This type of structure is, for example,... Figure 11 The structure shown allows for the production of transformer 3 in which winding units 30 and 31 are connected in series. By such a disconnection, multiple transformer 3 models can be easily manufactured by connecting winding units 30 and 31 in parallel or in series.

[0116] In this embodiment, the winding ends 2011, 2021, 2031, and 2041, which are the other of the two extension members, are interconnected. However, the structure connecting the winding ends 2011, 2021, 2031, and 2041 is not limited to this. A connecting portion may also be provided on the winding ends 2011, 2021, 2031, and 2041 to connect the winding ends 2011, 2021, 2031, and 2041 to each other.

[0117] As described above, in the transformer 3 according to Embodiment 1, one or both of the primary winding and the secondary winding are divided into multiple segments. Each of the multiple segmented windings in at least one of the divided windings has a winding portion wound on the core portion and two extension members extending from both ends of the winding portion. The first connection portion is connected to one of the two extension members of each of the multiple segmented windings in at least one of the divided windings. When the first connection portion 40a has two first conductive portions, each of the two first conductive portions is an external connection portion and an interconnection portion that connects two or more extension members to each other. When the first connection portion 40a has three or more first conductive portions, each of the two specific first conductive portions is an external connection portion, or an external connection portion and an interconnection portion. Each of one or more non-specific first conductive portions other than the two specific first conductive portions is an interconnection portion. Therefore, the series connection and parallel connection of the segmented windings are switched by the connection of the extension members in the first connection portion 40a, thereby enabling the number of turns of the transformer 3 to be changed while maintaining commonality without changing the core portion and the winding portion.

[0118] Therefore, since it can easily accommodate various input voltage specifications, there is no need to redesign the core and split windings, allowing for the common use of materials constituting the transformer 3. This commonality of materials reduces design time when changing the number of turns and minimizes the increase in the variety of transformer 3 types due to specialized designs, simplifying production and inventory management during transformer 3 manufacturing and thus improving the productivity of the transformer 3. Furthermore, the series and parallel connections of the split windings can be easily switched in the first connection section 40a.

[0119] When multiple first conductive portions are cut and formed at the insulation gap, multiple first conductive portions can be easily formed. Since multiple first conductive portions can be easily formed, the productivity of transformer 3 can be improved. Furthermore, when the other side of the two extension members of each of the multiple segmented windings in at least one segmented winding is connected to each other, the number of extension members that extend further outward than the winding portion of each of the multiple segmented windings can be reduced, thus simplifying the structure of the extension members.

[0120] When the transformer 3 is a planar transformer and multiple winding members are stacked along the extension direction of the winding shaft 103, more connection patterns can be formed in the first connection portion 40a because multiple extension members can be included. Furthermore, in the case where one of the two extension members of each of the multiple segmented windings in the at least one divided winding extends from an end away from the winding shaft 103, and the other of the two extension members of each of the multiple segmented windings in the at least one divided winding extends from an end close to the winding shaft 103, since the first connection portion 40a can be positioned further outward than the winding portion and away from the winding shaft 103, it is easy to cut off the cut portion of the first connection portion 40a, thus making it easy to change the number of turns of the primary winding 3a.

[0121] When the first connection portion 40a is formed of plate-shaped metal and either of the two extension members of each of the plurality of segmented windings in at least one segmented winding is integrated, the process of connecting the extension member integrated with the first connection portion 40a and the first connection portion 40a is not required, thus improving the productivity of the transformer 3. When the segmented winding having the extension member integrated with the first connection portion 40a is arranged on the outermost side in the stacked winding members when viewed along the extension direction of the winding shaft 103, the bending directions of the bending structures 2013, 2023, and 2033 of the extension members of the winding members can be unified, so the connection between the winding ends 2012, 2022, and 2032 and the first connection portion 40a can be easily performed from one direction.

[0122] In a configuration where multiple winding members, viewed along the extension direction of the winding shaft 103, have at least one first winding member and at least one second winding member, and the at least one first winding member has a winding portion wound clockwise on the winding shaft 103, and the at least one second winding member has a winding portion wound counterclockwise on the winding shaft 103, by connecting one first winding member and one second winding member in series, windings with the same winding direction of the winding shaft 103 can be easily constructed. In a winding unit formed by the first winding member and the second winding member, where the ends of the first winding member and the second winding member in the winding unit are connected to each other on the side closest to the winding shaft 103, and each extending member extends from the end furthest from the winding shaft 103, in a structure with a winding unit, the first connecting portion 40a can be easily positioned further outward than the winding portion, furthest from the winding shaft 103.

[0123] When multiple winding units are present, the number of turns and the winding direction of the multiple winding units are the same, and the first connecting part 40a connects the extension members of the multiple winding units in series or parallel, the series or parallel connection of the multiple arranged winding units can be easily changed by the first connecting part 40a, thereby easily changing the number of turns of the transformer 3. When the winding with a larger number of turns in the primary and secondary windings is one of multiple segmented windings in at least one segmented winding, the first connecting part 40a is provided on the winding with a larger number of turns to change the number of turns, thereby enabling the configuration of more connection modes for the extension members. Furthermore, the number of turns in the other winding can be easily adjusted to the turns ratio required for the transformer.

[0124] When the primary and secondary windings are partially or entirely sealed by the resin member 301, the insulation performance of each winding can be ensured by covering the spaces between the windings and the outer periphery of each winding with the resin member 301. When a portion of the interconnection is exposed from the resin member 301, that portion of the interconnection can be easily cut off. Furthermore, when the transformer 3 includes a cooler 302, the resin member 301 has an exposed portion 301a, and one or both of the primary winding 3a and secondary windings 3b and 3c are thermally connected to the cooler 302 at the exposed portion 301a via a heat-conducting member 303, the heat generation of the transformer 3 can be suppressed. The power conversion device 100 includes: a plurality of semiconductor switching elements 2a, 2b, 2c, and 2d, which are connected to a DC power supply to convert input DC power into AC power and output it; a transformer 3 as described in this embodiment, which converts the voltage of the AC power output from the plurality of semiconductor switching elements 2a, 2b, 2c, and 2d and outputs it; and a rectifier circuit 4, which rectifies the output of the transformer 3. In this case, various input voltage specifications can be easily accommodated, and a power conversion device 100 with improved productivity can be obtained.

[0125] Implementation method 2.

[0126] The transformer 3 involved in Implementation Method 2 will be described. Figure 23 This is an exploded perspective view showing the outline of the primary winding 3a, the first connection portion 40a, and the second connection portion 40b of the transformer 3 according to Embodiment 2. Figure 24 This is a top view showing the outline of the first connection part 40a and the second connection part 40b of the transformer 3. Figure 25 This is a top view showing the outline of the primary winding 3a, the first connection 40a, and the second connection 40b of the transformer 3. Figure 26 This is a side view showing an outline of the primary winding 3a and the first connection portion 40a of the transformer 3. Figure 27 Is Figure 25 A cross-sectional view of the primary winding 3a of transformer 3 cut off at section AA. Figure 28 This is a wiring diagram of the primary winding 3a, the first connection part 40a, and the second connection part 40b of transformer 3. Figure 29 This is a diagram showing the remaining wiring structure of the primary winding 3a, the first connection part 40a, and the second connection part 40b of transformer 3. Figure 30 This is a diagram showing the wiring structure of the primary winding 3a, the first connection portion 40a, and the second connection portion 40b of the transformer 3. In addition to the structure of Embodiment 1, the transformer 3 according to Embodiment 2 is also configured to include the second connection portion 40b and the connecting device 600.

[0127] <Second connecting part 40b, connecting device 600>

[0128] First, let's describe the structure that differs from Embodiment 1. The transformer 3 includes a second connection portion 40b, which has a plurality of second conductive portions arranged with insulating spaces between them. Figure 23 The second connection portion 40b is shown before the insulation interval is set. The second connection portion 40b is made of a plate-shaped metal such as copper. The second connection portion 40b is connected to the other of two extension members of each of the plurality of segmented windings in at least one segmented winding. In this embodiment, the second connection portion 40b is integrated with the winding end 5051 of the fifth primary winding 505, which serves as an extension member. Each of the plurality of second conductive portions is an interconnecting portion that connects two or more extension members to each other. By providing the second connection portion 40b, more connection patterns of extension members can be configured compared to Embodiment 1. Since more connection patterns of extension members can be configured, more types of turns can be configured in the transformer 3. Specific examples of connection patterns of extension members will be described later.

[0129] The transformer 3 includes a connecting device 600 that connects the first connecting portion 40a and the second connecting portion 40b. The connecting device 600 is made of a conductive metal such as copper. The connecting device 600 can be formed by bending a metal plate or by bending a rod-shaped metal. The connecting device 600 has bending structures 6013 and 6014 and is provided across the winding portion of the split winding. In the connecting device 600, a connecting end 6011 is formed at the end near the winding shaft 103, and a connecting end 6012 is formed at the end away from the winding shaft 103. The connecting end 6011, as an extension member of the connecting device 600, is connected to the second connecting portion 40b, and the connecting end 6012, as an extension member of the connecting device 600, is connected to the first connecting portion 40a. By providing the connecting device 600, more connection modes with extension members can be configured compared to Embodiment 1. Because more connection patterns for extending the components can be formed, a wider variety of turns can be constructed in the transformer 3. Furthermore, the transformer 3 is not limited to a structure having the connecting device 600; it can also be a transformer with a first connecting portion 40a and a second connecting portion 40b, or it can be a structure without the connecting device 600.

[0130] The first connecting portion 40a is disposed on one of the inner and outer sides of the winding portion, and the second connecting portion 40b is disposed on the other of the inner and outer sides of the winding portion. In this embodiment, the first connecting portion 40a is disposed on the outer side of the winding portion, and the second connecting portion 40b is disposed on the inner side of the winding portion. With this configuration, since the extension members of the segmented winding are concentrated on the inner and outer sides of the winding portion, the structure of the extension members of the segmented winding can be simplified.

[0131] <Structure of primary winding 3a>

[0132] An example of a primary winding 3a is shown, in which the number of turns N2 of the secondary windings 3b and 3c is set to N2 = 1, and the number of turns N1 of the primary winding 3a is set to N1 = 9, N1 = 12, or N1 = 15. In this embodiment, the winding member of the primary winding 3a is... Figure 23 The primary windings are sequentially stacked on the negative Z-axis side to form a first primary winding 501, a second primary winding 502, a third primary winding 503, a fourth primary winding 504, and a fifth primary winding 505. In this embodiment, the first primary winding 501, the third primary winding 503, and the fifth primary winding 505 are the first winding components, and the second primary winding 502 and the fourth primary winding 504 are the second winding components.

[0133] The complete winding is formed by a first winding member and a second winding member. The transformer 3 includes multiple complete windings and a first winding member or a second winding member. The first connection 40a is connected to one of the two extension members of each of the multiple complete windings and the first winding member or the second winding member. The second connection 40b is connected to the other of the two extension members of each of the multiple complete windings and the first winding member or the second winding member. The first connection 40a and the second connection 40b connect the extension members of the multiple complete windings in series with the extension members of the first winding member or the second winding member in parallel. In this embodiment, the complete winding 50 is formed by a second primary winding 502 and a third primary winding 503, and the complete winding 51 is formed by a fourth primary winding 504 and a fifth primary winding 505. Transformer 3 includes two sets of windings 50 and 51 and a first primary winding 501 as a first winding component.

[0134] The first primary winding 501, the second primary winding 502, the third primary winding 503, the fourth primary winding 504, and the fifth primary winding 505 are each wound three turns on the winding shaft 103 and have winding ends 5011, 5021, 5031, 5041, and 5051 as extension members near the winding shaft 103. The first primary winding 501, the second primary winding 502, the third primary winding 503, the fourth primary winding 504, and the fifth primary winding 505 have winding ends 5012, 5022, 5032, 5042, and 5052 as extension members away from the winding shaft 103. The first connecting portion 40a is integrated with the winding end 5052 of the fifth primary winding 505. Figure 23 As shown, winding ends 5011, 5021, 5031, and 5041 have bending structures 5013, 5023, 5033, and 5043 that bend in the Z direction for connection to the second connecting portion 40b. Winding ends 5012, 5022, 5032, and 5042 have bending structures 5014, 5024, 5034, and 5044 that bend in the Z direction for connection to the first connecting portion 40a.

[0135] like Figure 24As shown, the first connecting portion 40a has: through holes 81, 82, 83, 84, and 85 connecting the winding ends 5012, 5022, 5032, 5042 and the connecting end 6012; interconnecting portions 811, 821, 831, 841, and 851 connecting the winding ends 5012, 5022, 5032, 5042, 5052 and the connecting end 6012 to each other; and external connecting portions 8111 and 8211 connected to the outside. The second connecting portion 40b has: through holes 71, 72, 73, 74, and 75 connecting the winding ends 5011, 5021, 5031, 5041 and the connecting end 6011; and interconnecting portions 711, 721, 731, 741, and 751 connecting the winding ends 5011, 5021, 5031, 5041, 5051 and the connecting end 6011 to each other.

[0136] A portion of any one of the interconnecting portions 711, 721, 731, 741, 751, 811, 821, 831, 841, and 851 is cut off to form an insulating gap. A portion of any one of the interconnecting portions 811, 821, 831, 841, and 851 is disconnected, forming a plurality of first conductive portions arranged with insulating gaps between each other from the first connection portion 40a. A portion of any one of the interconnecting portions 711, 721, 731, 741, and 751 is disconnected, forming a plurality of second conductive portions arranged with insulating gaps between each other from the second connection portion 40b. When multiple second conductive portions are formed by cutting at the insulating gaps, multiple second conductive portions can be easily formed. Because multiple second conductive portions can be easily formed, the productivity of the transformer 3 can be improved. A portion of these interconnecting portions is exposed from the resin member 301 (not shown), so a portion of the interconnecting portion can be easily cut off.

[0137] like Figure 26 As shown, winding end 5032 is connected to through hole 81, winding end 5042 is connected to through hole 82, winding end 5012 is connected to through hole 83, winding end 5022 is connected to through hole 84, and connecting end 6012 is connected to through hole 85. Figure 27 As shown, winding end 5041 is connected to through hole 71, winding end 5031 is connected to through hole 72, winding end 5021 is connected to through hole 73, winding end 5011 is connected to through hole 74, and connecting end 6011 is connected to through hole 75. The winding end and connecting end pass through the through holes and are connected by, for example, solder (not shown). Since the structure is such that the winding end and connecting end are connected at the through hole, the connection structure in the first connecting part 40a and the second connecting part 40b is simplified, thereby improving the productivity of transformer 3.

[0138] The structure of a primary winding 3a with 15 turns N1 is described. In the case of forming 15 turns, portions of the interconnecting parts 811, 831, and 851 in the first connecting portion 40a are removed, for example, by tie rod cutting. Four first conductive portions are formed by forming insulating gaps in the interconnecting parts 811, 831, and 851. The four first conductive portions are formed by cutting at three insulating gaps. In this embodiment, in... Figure 28 In the middle, the first conductive portions on both sides are two specific first conductive portions, which are external connection portions 8111 and 8211. The two first conductive portions in the center are non-specific first conductive portions, which are interconnection portions 821 and 841. The first primary winding 501 and the second primary winding 502 are connected in series through the interconnection portion 841, and the third primary winding 503 and the fourth primary winding 504 are connected in series through the interconnection portion 821.

[0139] Furthermore, portions of the interconnecting portions 721 and 741 in the second connecting portion 40b are removed, for example, by a tie rod cutting process. Three second conductive portions are formed by creating insulating gaps in the interconnecting portions 721 and 741. The three second conductive portions are formed by cutting at two insulating gaps. In this embodiment, in Figure 28 In this configuration, the three second conductive portions are interconnecting portions 711, 731, and 751. The second primary winding 502 and the third primary winding 503 are connected in series via interconnecting portion 731, the fourth primary winding 504 and the fifth primary winding 505 are connected in series via interconnecting portion 711, and the first primary winding 501 and the connector 600 are connected in series via interconnecting portion 751.

[0140] Through this structure, such as Figure 28 As shown, the complete winding 50 and the complete winding 51 are connected in series in the interconnection part 821 and are connected in series with the first primary winding 501, thus enabling the transformer 3 with a primary number of turns N1 = 15 turns.

[0141] The structure of a primary winding 3a with 12 turns N1 is described. In the case of 12 turns, for example, portions of the interconnecting portions 821 and 841 in the first connecting portion 40a are removed by tie rod cutting. Three first conductive portions are formed by forming insulating gaps in the interconnecting portions 821 and 841. The three first conductive portions are formed by cutting at two insulating gaps. In this embodiment, in... Figure 29In the middle, the first conductive portions on both sides are two specific first conductive portions, namely external connection portions 8111 and 8211. The first conductive portion in the center is a non-specific first conductive portion, namely interconnection portion 831. The first primary winding 501 and the fourth primary winding 504 are connected in series through interconnection portion 831, the third primary winding 503 and the fifth primary winding 505 are connected in series through interconnection portion 811, and the second primary winding 502 and the external connection portion 8211 are connected in series through interconnection portion 851.

[0142] Furthermore, portions of the interconnecting portions 731 and 751 in the second connecting portion 40b are removed, for example, by a tie rod cutting process. Two second conductive portions are formed by creating an insulating gap in the interconnecting portions 731 and 751. In this structure, as... Figure 29 As shown, the portion without connecting device 600 is not used. Two second conductive portions are formed by being cut at two insulating intervals. In this embodiment, the two second conductive portions are interconnecting portions 711, 721 and interconnecting portion 741. The first primary winding 501 and the second primary winding 502 are connected in series via interconnecting portion 741, and the third primary winding 503, the fourth primary winding 504 and the fifth primary winding 505 are connected in parallel via interconnecting portions 711 and 721.

[0143] Through this structure, such as Figure 29 As shown, the third primary winding 503 and the fifth primary winding 505 are connected in parallel, and the fourth primary winding 504, the first primary winding 501, and the second primary winding 502 are connected in series, thereby enabling a transformer 3 with a primary number of turns N1 = 12 turns.

[0144] The structure of a primary winding 3a with 9 turns N1 is described. In the case of 9 turns, portions of the interconnecting portions 821 and 851 in the first connecting portion 40a are removed, for example, by tie rod cutting. Three first conductive portions are formed by forming insulating gaps in the interconnecting portions 821 and 851. The three first conductive portions are formed by cutting at two insulating gaps. In this embodiment, in... Figure 30 In the middle, the first conductive portions on both sides are two specific first conductive portions, namely external connection portions 8111 and 8211. The first conductive portion in the center is a non-specific first conductive portion, namely interconnection portions 831 and 841. The first primary winding 501, the second primary winding 502, and the fourth primary winding 504 are connected in parallel through interconnection portions 831 and 841, the third primary winding 503 and the fifth primary winding 505 are connected in series through interconnection portion 811, and the connector 600 is connected to the external connection portion 8211.

[0145] Furthermore, a portion of the interconnecting portion 741 in the second connecting portion 40b is removed, for example, by a tie rod cutting process. Two second conductive portions are formed by creating an insulating gap in the interconnecting portion 741. The two second conductive portions are formed by cutting at an insulating gap. In this embodiment, the two second conductive portions are interconnecting portions 711, 721, 731 and interconnecting portion 751. The second primary winding 502, the third primary winding 503, the fourth primary winding 504 and the fifth primary winding 505 are connected in parallel via interconnecting portions 711, 721, and 731, and the first primary winding 501 and the connector 600 are connected in series via interconnecting portion 751.

[0146] Through this structure, such as Figure 30 As shown, the complete winding 50 and the complete winding 51 are connected in parallel in the interconnection part 811 and connected in series with the first primary winding 501, thus enabling the transformer 3 with a primary number of turns N1 = 9 turns.

[0147] As described above, by switching the series and parallel connections of each segmented winding in the first connection portion 40a having multiple first conductive portions arranged with insulating intervals between each other, and the second connection portion 40b having multiple second conductive portions arranged with insulating intervals between each other, it is possible to switch the number of turns N1 of the primary winding 3a to 9 turns, 12 turns, and 15 turns while maintaining commonality and without changing the core portion and winding portion of the segmented windings of the transformer 3. Therefore, since various input voltage specifications can be easily accommodated, it is not necessary to redesign the core portion and winding components of the transformer 3, thus allowing for the commonality of the types of materials constituting the transformer 3. Because the types of materials constituting the transformer 3 are common, the design time for changing the number of turns and the increase in the types of transformers 3 due to dedicated designs can be suppressed, making production management and inventory management during the manufacture of the transformer 3 easier, thereby improving the productivity of the transformer 3. Since the switching between series and parallel connections of each segmented winding can be performed in the first connection part 40a and the second connection part 40b, it is not necessary to prepare and replace special components corresponding to each connection in order to change the connection, and production management and inventory management can be easily carried out during manufacturing.

[0148] In Embodiment 2, an example is shown in which a first connecting portion 40a and a second connecting portion 40b are provided at both ends of one segmented winding within each segmented winding of the primary winding 3a, and a connecting device 600 is provided. However, the embodiment is not limited to having all of these structures. For example, the structure of Embodiment 1 is provided with the first connecting portion 40a and the second connecting portion 40b, and it can be constructed even without the connecting device 600. Furthermore, when the first connecting portion 40a and the second connecting portion 40b are provided and the connecting device 600 is provided, the number of turns of the primary winding 3a can be configured into three patterns: the two patterns of 12 turns and 6 turns shown in Embodiment 1, plus the three patterns of 9 turns.

[0149] Furthermore, comparing transformers 3 with primary turns N1 of 15 turns, 12 turns, and 9 turns, the current increases accordingly due to the decrease in primary turns N1. When transformer 3 is installed in the housing of power conversion device 100, since transformer 3 has a planar structure, the cooler is positioned below the first primary winding 501. Therefore, the primary winding 3a and secondary windings 3b and 3c dissipate heat via the resin member 301 shown in Embodiment 1 along a path from the positive to the negative Z-axis. At this time, the third primary winding 503, the fourth primary winding 50, and the fifth primary winding 505, positioned on the positive Z-axis side, do not dissipate heat easily. In this embodiment, in the transformer 3 with a primary turn count N1 of 12 turns, the third primary winding 503 and the fifth primary winding 505 are connected in parallel. In the transformer 3 with a primary turn count N1 of 9 turns, the third primary winding 503 and the fifth primary winding 505, as well as the second primary winding 502 and the fourth primary winding 504, are connected in parallel. By configuring the split windings in parallel, the current flowing through them can be halved. While split windings located on the positive Z-axis side are not prone to heat dissipation, by connecting the split windings located on the positive Z-axis side in parallel, the heat generated by the increased current due to the corresponding increase in the turns ratio can be addressed.

[0150] <Product Group 3 of Transformer>

[0151] This describes a transformer product group comprising multiple transformer types 3. Each of the multiple transformer types 3, in addition to the structure of the multiple transformer types 3 shown in Embodiment 1, also includes a second connection portion having multiple second conductive portions arranged with insulating intervals between them. The second connection portion is connected to the other side of two extension members of each of the multiple segmented windings in at least one segmented winding. The portion of the second connection portion connected to the other side of the two extension members of each of the multiple segmented windings serves as the connected portion of the second connection portion. The connected portions of the multiple second connection portions are arranged with spacing intervals. Insulating intervals are provided in the spacing intervals. The spacing intervals with insulating intervals in the second connection portions differ between different transformer types 3, and the second conductive portions are present in the spacing intervals without insulating intervals.

[0152] By assembling the transformer 3 into this product group, it is easy to manage multiple models of transformer 3 with different connection structures in the first and second connection sections as a product group. Since production and inventory management during the manufacture of transformer 3 becomes easier, the productivity of transformer 3 can be improved.

[0153] <Manufacturing Method of Transformer 3>

[0154] Regarding the manufacturing method of transformer 3, a process different from that shown in Embodiment 1 will be described. In the component preparation process of transformer 3 according to this embodiment, a second connecting member, which will become the second connecting part 40b, is also prepared. In the connection process, one or both of the primary winding and the secondary winding are connected to the second connecting member. The other side of the two extension members of each of the plurality of divided windings in at least one divided winding is connected to the second connecting member with a configuration interval between them. In the cutting process, depending on the type of transformer, different configuration intervals are cut within the plurality of configuration intervals in the second connecting member.

[0155] By manufacturing the transformer 3 in this manner, the type of transformer can be easily changed during the cutting process by cutting different configuration intervals in the first and second connecting members, thus enabling the easy manufacture of multiple types of transformer 3. Since multiple types of transformer 3 can be easily manufactured, the productivity of producing multiple types of transformer 3 can be improved.

[0156] As described above, the transformer 3 according to Embodiment 2 includes a second connection portion 40b having a plurality of second conductive portions arranged with insulating intervals between them. The second connection portion 40b is connected to the other side of two extension members of each of the plurality of segmented windings in at least one segmented winding. Each of the plurality of second conductive portions is an interconnecting portion that connects two or more extension members to each other. Therefore, compared with Embodiment 1, more connection patterns of extension members can be formed. Since more connection patterns of extension members can be formed, more types of turns can be formed in the transformer 3. In addition, since various input voltage specifications can be easily accommodated, it is not necessary to redesign the core and segmented windings, and the types of materials constituting the transformer 3 can be shared. Since the types of materials constituting the transformer 3 are shared, the design time when changing the number of turns and the increase in the types of transformer 3 due to special designs can be suppressed, making production management and inventory management during the manufacture of the transformer 3 easier, thereby improving the productivity of the transformer 3.

[0157] When multiple second conductive portions are cut and formed at the insulation gap, multiple second conductive portions can be easily formed. Since multiple second conductive portions can be easily formed, the productivity of the transformer 3 can be improved. Furthermore, when a connecting device 600 connecting the first connecting portion 40a and the second connecting portion 40b is provided, more connection patterns with extension members can be configured compared to Embodiment 1. Since more connection patterns with extension members can be configured, more types of turns can be configured in the transformer 3. Moreover, when the first connecting portion 40a is disposed on one side of the inner and outer sides of the winding portion, and the second connecting portion 40b is disposed on the other side of the inner and outer sides of the winding portion, since the extension members of the split winding are concentrated on the inner and outer sides of the winding portion, the structure of the extension members of the split winding can be simplified.

[0158] It comprises: a first connecting portion 40a and a second connecting portion 40b, the first connecting portion 40a having a plurality of first conductive portions arranged with insulating gaps between them, and the second connecting portion 40b having a plurality of second conductive portions arranged with insulating gaps between them; a plurality of bundled windings, the plurality of bundled windings being composed of a first winding member and a second winding member; and a first winding member or a second winding member, wherein the first connecting portion 40a is connected to one of two extension members of each of the plurality of bundled windings and the first winding member or the second winding member. The second connection is connected to the other side of each of the two extension members of a plurality of complete windings and a first winding member or a second winding member. The first connection 40a and the second connection 40b connect the extension members of the plurality of complete windings to the extension members of a first winding member or a second winding member in series or in parallel. In the above case, by switching the series connection and parallel connection of each segmented winding, it is possible to form more types of turns in the transformer 3 while maintaining commonality and without changing the core part of the transformer 3 and the winding part of the segmented winding.

[0159] Implementation method 3.

[0160] The transformer 3 involved in Implementation Method 3 will be described. Figure 31 This is a wiring diagram of the primary winding 3a, the first connection portion 40a, and the second connection portion 40b of the transformer 3 according to Embodiment 3. Figure 32 This is a top view showing the outline of the first connection portion 40a and the second connection portion 40b of the transformer 3. The transformer 3 according to Embodiment 3 has a first connection portion 40a with a different structure than that of Embodiment 2, which is a primary winding 3a with a primary winding 3a having a primary winding 3a with a primary winding 3a having a primary winding 3a of 6 turns N1. The structure other than the first connection portion 40a is the same as that of Embodiment 2, so the description of the same structure is omitted.

[0161] like Figure 32 As shown, the first connecting portion 40a has: through holes 91, 92, 93, 94, and 95 connecting the winding ends 5012, 5022, 5032, and 5042 to the connecting end 6012; interconnecting portions 911, 921, 931, 941, and 951 connecting the winding ends 5012, 5022, 5032, 5042, and 5052 to the connecting end 6012; and external connecting portions 9111, 9211, and 9311 connected to the outside. The first connecting portion 40a also has interconnecting portions 961, 971, and 981 formed parallel to the y-axis, and interconnecting portions 1002, 1003, and 1005 formed to connect them. Each interconnecting portion is a portion in which an insulating gap is formed by cutting off any one of them.

[0162] like Figure 31As shown, winding end 5032 is connected to through hole 91, winding end 5042 is connected to through hole 92, winding end 5022 is connected to through hole 93, winding end 5012 is connected to through hole 94, and connecting end 6012 is connected to through hole 95. Additionally, winding end 5041 is connected to through hole 71, winding end 5031 is connected to through hole 72, winding end 5021 is connected to through hole 73, winding end 5011 is connected to through hole 74, and connecting end 6011 is connected to through hole 75. The winding ends and connecting ends pass through the through holes and are connected by, for example, solder (not shown).

[0163] The structure of a primary winding 3a with a turn count N1 of 6 turns is described. In the case of 6 turns, portions of the interconnecting portions 921, 941, 951, and 1003 in the first connecting portion 40a are removed, for example, by a tie rod cutting process. Two first conductive portions are formed by creating insulating gaps in the interconnecting portions 921, 941, 951, and 1003. Due to the forming of insulating gaps, the first primary winding 501, the third primary winding 503, and the fifth primary winding 505 are connected in parallel via interconnecting portions 911, 961, 971, 981, 1002, and 1005. The second primary winding 502 and the fourth primary winding 504 are connected in series via interconnecting portion 931.

[0164] Furthermore, a portion of the interconnecting portion 751 in the second connecting portion 40b is removed, for example, by a tie rod cutting process. An insulating gap is formed in the interconnecting portion 751, thereby forming a second conductive portion. The second conductive portion is one because the connecting device 600 is not used in this embodiment. Since the connecting device 600 is not used, the external connecting portion 9211 connected to the connecting device 600 is also not used. The first primary winding 501, the second primary winding 502, the third primary winding 503, the fourth primary winding 504, and the fifth primary winding 505 are connected in parallel via the interconnecting portions 711, 721, 731, and 741. Because of the presence of a second conductive portion, it is also possible to connect the winding ends of each segmented winding to each other without providing the second connecting portion 40b. Since this embodiment is described as a variation of Embodiment 2, it is configured to include the connecting device 600 and the second connecting portion 40b.

[0165] Through this structure, such as Figure 31 As shown, since the first primary winding 501, the third primary winding 503 and the fifth primary winding 505 are connected in parallel, and the second primary winding 502 and the fourth primary winding 504 are connected in series, a transformer 3 with a primary number of turns N1 = 6 turns can be realized.

[0166] When using the first connection portion 40a and the second connection portion 40b according to this embodiment, by setting any one of the interconnecting portions as an insulating gap, a transformer 3 with primary turns N1 = 15, 12, 9, 6, or 3 turns can be realized. Thus, by changing the structure of the first connection portion 40a, even when using a split winding with the same number of turns and layers as in Embodiment 2, the number of turns in the primary winding 3a can be changed. Regardless of the number of turns and layers in a split winding, the first connection portion 40a and the second connection portion 40b are provided at the ends of the split winding, thereby enabling a transformer 3 with a changeable number of turns.

[0167] Furthermore, although this application describes various exemplary implementation methods and embodiments, the various features, methods and functions described in one or more implementation methods are not limited to specific implementation methods, but can also be applied to implementation methods individually, or in various combinations to be applied to implementation methods.

[0168] Therefore, it can be assumed that numerous variations not illustrated are also included within the scope of the technology disclosed in this application. For example, this includes cases where at least one constituent element is modified, added to, or omitted, and cases where at least one constituent element is extracted and combined with constituent elements of other embodiments.

[0169] Label Explanation

[0170] 1 DC power supply

[0171] 2 Single-phase inverters

[0172] 2a, 2b, 2c, 2d Semiconductor switching elements

[0173] 3 transformers

[0174] 3a primary winding

[0175] 3b secondary winding

[0176] 3C secondary winding

[0177] 4 Rectifier Circuit

[0178] Diodes 4a and 4b

[0179] 5 reactors

[0180] 6 filter capacitors

[0181] 7 load

[0182] Winding units 30, 31, 32, and 33

[0183] 40a First connecting part

[0184] 40b Second Connection

[0185] 50 and 51 complete winding sets

[0186] 100 power conversion device

[0187] 101 lower side core

[0188] 102 upper side core

[0189] 103 winding shaft

[0190] 103a winding axis

[0191] 201, 205, 501 First primary winding

[0192] 202, 502 Second primary winding

[0193] 203, 206, 503 Third primary winding

[0194] 204 and 504 fourth primary winding

[0195] 505 Fifth Primary Winding

[0196] 300 winding body

[0197] 301 resin components

[0198] 301a Exposed Part

[0199] 302 Cooler

[0200] 303 thermal conductive components

[0201] 2011, 2021, 2031, 2041, 2051, 2061, 2012, 2022, 2032, 2042, 2052, 2062, 5011, 5021, 5031, 5041, 5051, 5012, 5022, 5032, 5042, 5052 winding ends

[0202] 2013, 2023, 2033, 5013, 5023, 5033, 5043, 5014, 5024, 5034, 5044, 6013, 6014 bending structures

[0203] Through holes 41, 42, 43, 44, 71, 72, 73, 74, 75, 81, 82, 83, 84, 85, 91, 92, 93, 94, 95

[0204] Interconnection sections 411, 421, 431, 711, 721, 731, 741, 751, 811, 821, 831, 841, 851, 911, 921, 931, 941, 951, 961, 971, 981, 1002, 1003, 1005

[0205] Insulation gaps 451, 461, and 471

[0206] External connection parts 4111, 4211, 8111, 8211, 9111, 9211, 9311

[0207] 600 Connecting Devices

[0208] 6011, 6012 connection ends.

Claims

1. A transformer, characterized in that, include: The core portion forms a magnetic circuit; A primary winding and a secondary winding are wound on the core portion; as well as The first connecting portion has a plurality of first conductive portions arranged with insulating intervals between them. One or both of the primary winding and the secondary winding are divided into a plurality of windings, and each of the plurality of divided windings in at least one of the divided windings has a wound portion wound on the core portion and two extension members extending from both ends of the wound portion. The first connecting portion is connected to one of the two extension members of each of the plurality of segmented windings in at least one segmented winding. In the case where the first connecting portion has two first conductive portions, each of the two first conductive portions is an external connecting portion connected to the outside, and is an interconnecting portion that connects two or more of the extension members to each other. In the case where the first connection portion has three or more first conductive portions, each of the two specific first conductive portions is the external connection portion, or the external connection portion is also the interconnect portion, and one or more non-specific first conductive portions other than the two specific first conductive portions are the interconnect portions.

2. The transformer as described in claim 1, characterized in that, Multiple first conductive portions are formed by cutting them at the insulating gap.

3. The transformer as described in claim 1 or 2, characterized in that, The second connection portion includes a plurality of second conductive portions arranged with insulating intervals between them. The second connecting portion is connected to the other side of each of the two extension members of each of the plurality of segmented windings in at least one of the segmented windings. Each of the plurality of the second conductive portions is an interconnection portion that connects two or more of the extended members to each other.

4. The transformer as described in claim 3, characterized in that, Multiple of the second conductive portions are formed by cutting them at the insulating gap.

5. The transformer as described in claim 3 or 4, characterized in that, It includes a connecting device that connects the first connecting part and the second connecting part.

6. The transformer as described in claim 1 or 2, characterized in that, The other side of each of the two extension members of each of the plurality of divided windings in at least one divided winding is interconnected.

7. The transformer as described in any one of claims 3 to 5, characterized in that, The first connecting portion is disposed on one side of the inner and outer sides of the wound portion. The second connecting portion is disposed on the other side of the inner and outer sides of the winding portion.

8. The transformer as described in any one of claims 1 to 7, characterized in that, The primary winding and the secondary winding are formed by multiple winding components. Each of the plurality of winding members is formed as a plate bent in the same plane orthogonal to the extension direction of the winding axis, which is part of the core portion, and the plate surface is orthogonal to the extension direction of the winding axis. The plurality of winding components are stacked in the extension direction of the winding shaft.

9. The transformer as described in claim 8, characterized in that, In at least one of the split windings, one end of each of the two extension members of each of the split windings extends from the end on the side away from the winding shaft. In at least one of the divided windings, the other side of each of the two extension members of each of the divided windings extends from an end near the side of the winding shaft.

10. The transformer as described in claim 8, characterized in that, The first connecting part is made of plate-shaped metal. The first connecting portion is integrated with either of the two extension members of each of the plurality of divided windings in at least one of the divided windings.

11. The transformer as described in claim 10, characterized in that, Viewed along the extension direction of the winding shaft, the segmented winding having the extension member integrated with the first connecting portion is arranged on the outermost side among the stacked winding members.

12. The transformer according to any one of claims 8 to 11, characterized in that, Viewed along the extension direction of the winding shaft, the plurality of winding members have at least one first winding member and at least one second winding member, the at least one first winding member having a winding portion that is wound clockwise on the winding shaft from a side away from the winding shaft toward a side close to the winding shaft, and the at least one second winding member having a winding portion that is wound counterclockwise on the winding shaft from a side away from the winding shaft toward a side close to the winding shaft.

13. The transformer as described in claim 12, characterized in that, It has a winding unit, which is formed by one of the first winding members and one of the second winding members. The ends of the first winding member and the second winding member in the winding unit are connected to each other on the side near the winding shaft, and each of the extension members extends from the end on the side away from the winding shaft.

14. The transformer as described in claim 13, characterized in that, Having multiple winding units, The winding directions of the plurality of winding units are the same as those of each other. The first connecting part connects the extension members of the plurality of winding units in series or in parallel.

15. The transformer as described in claim 12, characterized in that, have: A plurality of complete windings consisting of a first winding member and a second winding member, and a first winding member or a second winding member; as well as A second connecting portion having a plurality of second conductive portions arranged with insulating intervals between them. The first connecting portion is connected to one of the two extension members of each of the plurality of said bundled windings and a first winding member or a second winding member. The second connecting portion is connected to the other side of each of the two extension members of each of the plurality of said bundled windings and one of the first winding members or one of the second winding members. The first connecting part and the second connecting part connect the extension members of the plurality of sets of windings and the extension members of a first winding member or a second winding member in series or in parallel.

16. The transformer according to any one of claims 1 to 15, characterized in that, In the primary winding and the secondary winding, the winding with more turns in the winding portion is one of the multiple segmented windings in at least one of the segmented windings.

17. The transformer according to any one of claims 1 to 16, characterized in that, The primary winding and part or all of the secondary winding are sealed with resin components.

18. The transformer as described in claim 17, characterized in that, A portion of the interconnecting portion is exposed from the resin component.

19. The transformer as described in claim 17, characterized in that, Includes a cooler that is thermally connected to the resin component. The resin component has an exposed portion on one side of the cooler, which exposes a portion of one or both of the primary winding and the secondary winding. One or both of the primary winding and the secondary winding are thermally connected to the cooler via a heat-conducting member at the exposed portion.

20. A power conversion device, characterized in that, include: Multiple semiconductor switching elements connected to a DC power supply to convert the input DC power into AC power and output it. A transformer as described in any one of claims 1 to 19, which converts and outputs the voltage of alternating current output from a plurality of said semiconductor switching elements; as well as A rectifier circuit that rectifies the output of the transformer.

21. A transformer product group comprising multiple types of transformers, said multiple types of transformers including: The core portion forms a magnetic circuit; A primary winding and a secondary winding are wound on the core portion; as well as The first connecting portion has a plurality of first conductive portions arranged with insulating intervals between them. One or both of the primary winding and the secondary winding are divided into multiple portions, each of the multiple divided windings in at least one of the divided windings including a wound portion wound on the core portion and two extending members extending from both ends of the wound portion. The product group of the transformer is characterized in that... The first connecting portion is connected to one of the two extension members of each of the plurality of segmented windings in at least one segmented winding. The portion of the first connection portion that connects to one of the two extension members of each of the plurality of segmented windings is designated as the connected portion. The plurality of connected portions are arranged with a configuration interval. The configuration intervals with the insulation interval are different between different types of transformers. The first conductive portion exists in the configuration intervals without the insulation interval.

22. The product group of transformers as described in claim 21, characterized in that, In the case where the first connecting portion has two first conductive portions, each of the two first conductive portions is an external connecting portion connected to the outside, and is an interconnecting portion that connects two or more of the extension members to each other. In the case where the first connection portion has three or more first conductive portions, each of the two specific first conductive portions is the external connection portion, or the external connection portion is also the interconnect portion, and each of the one or more non-specific first conductive portions other than the two specific first conductive portions is the interconnect portion.

23. The product group of transformers as described in claim 21 or 22, characterized in that, The second connection portion includes a plurality of second conductive portions arranged with insulating intervals between them. The second connecting portion is connected to the other of the two extending members of each of the plurality of segmented windings in at least one segmented winding. The portion of the second connecting part that connects to the other side of each of the two extension members of the plurality of segmented windings is designated as the connected portion of the second connecting part, and the connected portions of the plurality of second connecting parts are arranged at intervals. Among the different types of transformers, the configuration intervals in the second connection portion that are provided with the insulation interval are different, and the second conductive portion exists in the configuration intervals that are not provided with the insulation interval.

24. A method for manufacturing a transformer, characterized in that, include: The component preparation process for preparing the core, primary winding, secondary winding, and first connecting member to form the magnetic circuit; The winding process of winding the primary winding and the secondary winding onto the core portion; The connection process of connecting one or both of the primary winding and the secondary winding to the first connecting member; and The cutting process of cutting off the first connecting member. In the component preparation process, as the primary winding and the secondary winding, a winding is prepared such that one or both of the primary winding and the secondary winding are divided into a plurality of windings, and each of the plurality of divided windings in at least one of the divided windings has a winding portion wound on the core portion and two extension members extending from both ends of the winding portion. In the connection process, One side of each of the two extension members of each of the plurality of segmented windings in at least one of the segmented windings is connected to the first connecting member with a configuration interval between them. In the cutting process, Within the multiple configuration intervals, depending on the type of transformer, different portions of the configuration intervals are cut off.

25. The method for manufacturing a transformer as described in claim 24, characterized in that, In the cutting process, When the first connecting member is cut into two to form two conductive portions, each of the two conductive portions is an external connecting portion connected to the outside, and is cut into interconnecting portions that connect two or more of the extension members to each other. When the first connecting member is cut into three or more parts to form three or more conductive portions, each of the two specific conductive portions is either the external connecting portion or both the external connecting portion and the interconnecting portion, and each of the one or more non-specific conductive portions other than the two specific conductive portions is cut into the interconnecting portion. The cutting point is changed according to the type of transformer.

26. The method for manufacturing a transformer as described in claim 24 or 25, characterized in that, In the component preparation process, the second connecting component is prepared. In the connection process, one or both of the primary winding and the secondary winding are connected to the second connecting member. The other side of each of the two extension members of each of the plurality of split windings in at least one of the split windings is connected to the second connecting member with a configuration interval between them. In the cutting process, Within the plurality of configuration intervals in the second connecting member, different configuration intervals are cut off depending on the type of transformer.

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