transformer

Abstract

A transformer according to one embodiment includes a core unit, a first coil unit and a second coil unit, and a terminal coil holder coupled to one side of the second coil unit in a first direction, wherein the first coil unit includes a first coil, and a first coil holder, wherein the second coil unit includes a second coil, and a second coil holder, wherein the terminal coil holder includes a plurality of first terminals provided on one side of the terminal coil holder oriented in the first direction, and an opening formed in the other side opposite to the one side in the first direction to allow one side of the second coil unit to be inserted therein, and wherein both end portions of the first coil are led out from the first coil holder, and connected to different first terminals from each other among the plurality of first terminals of the terminal coil holder, respectively.

Description

Technical Field

[0001] This disclosure relates to a transformer. Background Technology

[0002] Various coil components (such as transformers or line filters) are installed in the power supply unit of electronic devices.

[0003] Transformers may be included in electronic devices for various purposes. For example, transformers can be used to perform energy transfer functions, moving energy from one circuit to another. Furthermore, transformers can be used to perform voltage boosting or bucking functions. Additionally, transformers, which exhibit only inductive coupling between the primary and secondary coils and therefore do not directly form a DC path, can be used to block direct current and apply alternating current, or to insulate between two circuits.

[0004] Figure 1 This is an exploded perspective view showing an example of the construction of a common transformer.

[0005] Reference Figure 1 A typical thin transformer 10 includes a core unit comprising an upper core 11 and a lower core 12, and includes a secondary coil 13 and a primary coil 14 disposed between cores 11 and 12. Typically, the secondary coil 13 consists of multiple conductive metal plates, and the primary coil 14 is in the form of wound wire. In another configuration, a coil frame (not shown) may be disposed between the upper core 11 and the lower core 12.

[0006] exist Figure 1 In the transformer shown, the primary and secondary coils overlap each other vertically. When a wire is used instead of a conductive metal plate for the secondary coil, the primary and secondary coils can be arranged to overlap each other horizontally.

[0007] However, when wires are used in secondary coils, to achieve a thinner profile, they need to be arranged parallel to each other when viewed in a plan view, thus forming turns around the central leg of the core unit. In this case, the inner wire closest to the central leg is the shortest, while the outer wire furthest from the central leg is the longest, resulting in a change in inductance. This change in inductance leads to current concentration, and this current concentration causes intense heat generation. Summary of the Invention

[0008] Technical issues

[0009] The technical objective of this disclosure is to provide a transformer having a thin structure that reduces heat generation and prevents heat generation due to changes in inductance caused by the length difference between the wires constituting the coil.

[0010] Another technical objective of this disclosure is to provide a thin transformer that can be further thinned while ensuring leakage inductance.

[0011] The technical tasks of this disclosure are not limited to those described above, and those skilled in the art will clearly understand from the following description other technical tasks not mentioned herein.

[0012] Technical solution

[0013] A transformer according to an embodiment includes: a core unit including an upper core and a lower core; a coil unit partially disposed in the core unit; and a coil frame unit disposed between the core unit and the coil unit, wherein the coil unit includes a first coil and a second coil at least partially disposed next to the first coil, wherein the coil frame unit includes a first coil frame and a second coil frame, the first coil frame having a first receiving portion formed therein to receive the first coil, the second coil frame having a second receiving portion formed therein to receive the second coil, wherein the first coil frame includes a first extension portion extending from the first receiving portion toward the second coil frame, and wherein the second receiving portion is disposed on the first extension portion.

[0014] The first coil frame may include a first top portion, a first bottom portion disposed below the first top portion, and a first intermediate portion disposed between the first top portion and the first bottom portion, the first intermediate portion having a first through-hole defined by its inner surface. A first extension portion may be disposed on the first bottom portion.

[0015] The second coil holder may include a second top portion having a second through hole formed therein, a second bottom portion disposed below the second top portion, and a second intermediate portion disposed between the second top portion and the second bottom portion. The first coil holder may be at least partially received in a recess defined by the lower surface of the second top portion and the inner surface of the second intermediate portion.

[0016] The first extension portion can face the lower surface of the second base portion.

[0017] The second top portion may include a first guide and a second guide (with a second through hole between them) facing each other in the long axis direction of the second coil frame, and each of the first guide and the second guide may protrude upward from the upper surface of the second top portion and may extend in the short axis direction of the second coil frame.

[0018] The upper core can be positioned between the first guide and the second guide.

[0019] The second top portion may also include a third through hole facing the second through hole in the long axis direction, and the second guide is located between the second through hole and the third through hole.

[0020] The first top portion may also include a coil lead portion disposed on its upper surface, and the coil lead portion may pass through a third through hole to be exposed.

[0021] The second top portion may also include a blind hole formed in its lower surface to extend into the interior of the second guide, and the first top portion may also include a protruding pin disposed between the coil lead portion and the first through hole and projecting upward from its upper surface to insert into the blind hole.

[0022] The shortest distance from the lower surface of the lower core to the first coil and the shortest distance from the lower surface of the lower core to the second coil can be different from each other.

[0023] The shortest distance from the lower surface of the lower core to the first coil can be shorter than the shortest distance from the lower surface of the lower core to the second coil.

[0024] The second coil frame may include a second extension extending from the second receiving portion toward the first coil frame, and the first receiving portion may be disposed below the second extension.

[0025] A portion of the second receiving section may be positioned between the first coil and the second coil.

[0026] The core unit may include a first outer pillar portion, a second outer pillar portion, and a central pillar portion disposed between the first outer pillar portion and the second outer pillar portion, and the shortest distance between the first coil and the second coil may be 0.1 to 0.3 times the shortest distance from the outermost periphery of the first coil to the outermost pillar portion adjacent to the outermost periphery of the first coil in the first outer pillar portion and the second outer pillar portion.

[0027] The core unit may also include a first space defined between the first outer pillar portion and the central pillar portion for receiving a portion of the coil frame unit, and a second space defined between the second outer pillar portion and the central pillar portion for receiving another portion of the coil frame unit.

[0028] The ratio of the second distance (the shortest distance between the first coil and the second coil in the first space or the second space) to the first distance (the shortest distance between the first coil and the second coil in the region outside the first space and the second space) can be 1 to 1.3.

[0029] The shortest distance from the lower surface of the lower core to the first coil can be 0.3 to 0.7 times the shortest distance from the lower surface of the lower core to the second coil.

[0030] According to another embodiment, a flat panel display device includes a power supply unit in which a transformer is disposed, wherein the transformer includes: a core unit including an upper core and a lower core; a coil unit partially disposed in the core unit; and a coil frame unit disposed between the core unit and the coil unit, wherein the coil unit includes a first coil and a second coil at least partially disposed next to the first coil, wherein the coil frame unit includes a first coil frame and a second coil frame, the first coil frame having a first receiving portion formed therein to receive the first coil, the second coil frame having a second receiving portion formed therein to receive the second coil, wherein the first coil frame includes a first extension portion extending from the first receiving portion to the second coil frame, and wherein the second receiving portion is disposed on the first extension portion.

[0031] According to another embodiment, a transformer includes: a core unit including an upper core and a lower core; a first coil unit and a second coil unit, at least partially disposed between the upper core and the lower core; and a terminal coil frame connected to one side of the second coil unit in a first direction, wherein the first coil unit includes a first coil and a first coil frame having a first through hole, a central support of the core unit passing through the first through hole, and the first coil frame receiving the first coil, wherein the second coil unit includes a second coil and a second coil frame having a second through hole receiving at least a portion of the first coil unit, and the second coil frame receiving the second coil, wherein the terminal coil frame includes a plurality of first terminals and an opening, the plurality of first terminals being spaced apart from each other in a second direction intersecting the first direction on one side of the terminal coil frame oriented in the first direction, the opening being formed on the other side opposite to one side in the first direction to allow one side of the second coil unit to be inserted therein, and wherein two ends of the first coil are led out from the first coil frame and respectively connected to different first terminals among the plurality of first terminals of the terminal coil frame.

[0032] The first coil frame may include a first top plate, a first bottom plate spaced apart from the first top plate in a third direction intersecting the first and second directions, and a first sidewall disposed between the first top plate and the first bottom plate. The first top plate may include a lead-out hole that allows two ends to be led out onto the first top plate through the lead-out hole.

[0033] The terminal coil holder may include a recess formed on its other side in a first direction, which may overlap with a lead-out slot in a third direction.

[0034] The terminal coil holder may include a plurality of first wire guides, which extend from the recess to a plurality of first terminals respectively, and the two ends of the first coil may be led out through lead-out slots and may extend along different first wire guides of the plurality of first wire guides to the respective first terminals.

[0035] The second coil frame may include a second top plate, a second bottom plate spaced apart from the second top plate in a third direction intersecting the first and second directions, and a second side wall disposed between the second top plate and the second bottom plate.

[0036] The transformer may include a first portion disposed on one side of the second coil frame in a first direction relative to the second through-hole, and a second portion disposed on the opposite side of the second through-hole opposite to the first portion. The second coil may include a plurality of conductors disposed around the second through-hole. One side of the plurality of conductors may extend to be disposed on the second portion, and another side of the plurality of conductors may extend such that both ends of the other side of the plurality of conductors are disposed on the first portion. The first and second conductors of the plurality of conductors at least partially overlap each other on the second portion. The second coil frame may include a recess that at least partially overlaps with the region in a third direction where the first and second conductors of the second portion overlap each other.

[0037] The recess can be formed in the second base plate.

[0038] The second coil frame may also include a plurality of second terminals disposed on the second base plate in the first part.

[0039] The first and second conductors may have symmetrical shapes relative to the second through hole in a first direction.

[0040] Multiple conductors may also include a third conductor that forms a turn outside the first conductor when viewed in a plan view and a fourth conductor that forms a turn outside the second conductor when viewed in a plan view.

[0041] The third conductor and the first conductor can be arranged in parallel to form a turn, and the fourth conductor and the second conductor can be arranged in parallel to form a turn.

[0042] The second top plate may include a first partition wall portion that projects upward in a third direction from an edge of the first portion oriented in a first direction and extends in a second direction.

[0043] The second coil frame may also include a second wire guide that extends in a first direction between the second sidewall and the plurality of second terminals.

[0044] The second coil frame may also include a second partition wall portion that protrudes downward from the second base plate in a third direction between the second through hole and the recess, and extends in a second direction.

[0045] The second coil frame may also include a first support portion and a second support portion, the first support portion protruding from the second partition wall portion toward the second through hole in a first direction, the second support portion facing the first support portion (the second through hole is located between the first support portion and the second support portion), and the first support portion and the second support portion can support the first coil unit.

[0046] According to another embodiment, a circuit board includes a substrate and a transformer disposed on the substrate, wherein the transformer includes: a core unit including an upper core and a lower core; a first coil unit and a second coil unit disposed at least partially between the upper core and the lower core; and a terminal coil holder coupled to one side of the second coil unit in a first direction, wherein the first coil unit includes a first coil and a first coil holder having a first through hole through which a central post of the core unit passes, and the first coil holder receives the first coil, wherein the second coil unit includes a second coil and a second coil holder having a second through hole for receiving at least a portion of the first coil unit, and the second coil holder receives the second coil, wherein the terminal coil holder includes a plurality of first terminals and an opening, the plurality of first terminals being disposed on one side of the terminal coil holder oriented in the first direction and spaced apart from each other in a second direction intersecting the first direction, the opening being formed on the opposite side in the first direction to allow one side of the second coil unit to be inserted therein, and wherein two ends of the first coil are led out from the first coil holder and respectively connected to different first terminals among the plurality of first terminals of the terminal coil holder.

[0047] Beneficial effects

[0048] The transformer according to the embodiment is configured such that multiple conductors constituting the coil intersect each other in a region, thereby minimizing the length difference between the conductors.

[0049] In addition, the terminal pins are short-circuited to each other, thereby reducing the inductance variation between the parallel wires that make up the same turn, and thus reducing heat generation.

[0050] Furthermore, the coil frame has openings formed in the areas where the wires intersect, thus enabling a thin profile.

[0051] In a transformer according to another embodiment, leakage inductance is ensured by controlling the spacing between the first coil unit and the second coil unit.

[0052] Furthermore, due to the coupling structure of the first and second coil frames, an insulation distance is ensured between the primary coil and the core, thereby ensuring leakage inductance.

[0053] The effects achievable through this disclosure are not limited to those described above, and those skilled in the art will clearly understand from the following description other effects not mentioned herein. Attached Figure Description

[0054] Figure 1 This is an exploded perspective view showing an example of the construction of a typical thin transformer.

[0055] Figure 2a This is a plan view of the transformer according to the implementation method.

[0056] Figure 2b This is a bottom view of the transformer according to this embodiment.

[0057] Figure 2c The transformer according to this embodiment is along Figure 2a The sectional view taken by line A-A' in the middle.

[0058] Figure 3a This is a perspective view of the first coil frame according to the embodiment.

[0059] Figure 3b This is a plan view of the first coil frame according to this embodiment.

[0060] Figure 4a This is a plan view of the second coil frame according to the embodiment.

[0061] Figure 4b This is a perspective view of the second coil frame according to this embodiment.

[0062] Figure 4c This is a rear perspective view of the second coil frame according to this embodiment.

[0063] Figure 5a This is a plan view of the terminal coil holder according to the embodiment.

[0064] Figure 5b This is a perspective view of the terminal coil frame according to this embodiment.

[0065] Figure 6 An example of a transformer with an adhesive portion configured according to this embodiment is shown.

[0066] Figure 7a An example of a coil being configured according to an embodiment of the second coil unit is shown.

[0067] Figure 7b A pin diagram of the second coil unit according to an embodiment is shown. Figure 7c This is a circuit diagram of a transformer according to an implementation method.

[0068] Figure 7d This is a view used to explain the overlapping pattern of the wires on the second part of the second coil unit according to the embodiment.

[0069] Figure 7eThis is a rear view of the second coil unit according to the embodiment. Figure 7f This is a side view of the second coil unit according to the embodiment.

[0070] Figure 7g This is a plan view showing an example of the construction of a second coil frame according to another embodiment.

[0071] Figure 8a This is a perspective view of a transformer according to yet another embodiment.

[0072] Figure 8b This is a plan view of a transformer according to yet another embodiment.

[0073] Figure 9 This is an exploded perspective view of a transformer according to yet another embodiment.

[0074] Figure 10 This is a perspective view of the first coil frame according to yet another embodiment.

[0075] Figure 11 This is an exploded perspective view of a coil frame unit according to another embodiment.

[0076] Figure 12 The transformer according to yet another embodiment Figure 8b The sectional view taken by line B-B' in the figure.

[0077] Figure 13a The transformer along according to yet another embodiment Figure 8b The sectional view taken by line A-A' in the middle.

[0078] Figure 13b yes Figure 13a Enlarged view of section C.

[0079] Figure 14 An example of the circuit construction of the power supply unit of an electronic product is shown. Detailed Implementation

[0080] The present disclosure will now be described more fully with reference to the accompanying drawings, in which various embodiments are illustrated. However, these examples may take many different forms and should not be construed as limiting the embodiments described herein. It should be understood that this disclosure covers all modifications, equivalents, and alternatives falling within the scope and spirit of this disclosure.

[0081] Ordinal numbers such as “second” and “first” may be used when describing various components, but they are not intended to limit these components. These expressions are only used to distinguish one component from another. For example, a second element may be referred to as a first element without departing from the scope of this disclosure, and similarly, a first element may be referred to as a second element. As used herein, the term “and / or” includes any and all combinations of one or more of the related listed items.

[0082] It should be understood that when a component is referred to as "connected" or "linked" to another component, it can be directly connected or linked to the other component, or there may be intermediate components. Conversely, when a component is referred to as "directly connected" or "directly linked" to another component, there are no intermediate components.

[0083] In the description of the embodiments, it should be understood that when an element such as a layer (film), region, pattern, or structure is referred to as being "on" or "under" another element (e.g., a substrate, layer (film), region, pad, or pattern), the terms "on" or "under" mean that the element is formed "directly" on or under the other element, or "indirectly," and thus intermediate elements may also be present. It should also be understood that the criteria for "on" or "under" are based on the accompanying drawings. Furthermore, for clarity and convenience of explanation, the thickness or dimensions of layers (films), regions, patterns, or structures shown in the drawings may be exaggerated, omitted, or schematically drawn, and may not accurately reflect actual dimensions.

[0084] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments of this disclosure. As used herein, the singular form is also intended to include the plural form unless the context clearly indicates otherwise. It should also be understood that the terms “comprising” or “having” as used herein specify the presence of the stated features, integers, steps, operations, elements, components, or combinations thereof, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

[0085] Unless otherwise defined, all terms used herein (including technical or scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art. Terms (e.g., those defined in a common dictionary) should be interpreted as having the same meaning as the term in the context of the relevant art and should not be interpreted as having an ideal or overly formal meaning unless expressly defined in the specification.

[0086] The transformer according to the embodiments will be described in detail below with reference to the accompanying drawings.

[0087] Figure 2a This is a plan view of the transformer according to the implementation method. Figure 2b This is a rear view of the transformer according to this embodiment. Figure 2c The transformer according to this embodiment is along Figure 2a The sectional view taken by line A-A' in the middle.

[0088] refer to Figures 2a to 2c The transformer 100 according to the embodiment may include core units 111 and 112, a first coil unit 120, a second coil unit 130, a terminal coil frame 140, and a core fixing unit 150. The various components will be described in detail below.

[0089] Core units 111 and 112 can function as magnetic circuits and thus serve as paths for magnetic flux. Core units 111 and 112 may include an upper core 111 located at an upper position and a lower core 112 located at a lower position. The two cores 111 and 112 can be formed symmetrically or asymmetrically with respect to each other in the vertical direction. However, for ease of explanation, the description assumes that the two cores are formed vertically symmetrically with respect to each other.

[0090] Each of the upper core 111 and the lower core 112 may include a body portion and a plurality of support portions. The body portion has a flat plate shape, and the plurality of support portions protrude from the body portion in the thickness direction (i.e., the third axial direction) and extend in a predetermined direction. When viewed in a plan view, the plurality of support portions may include two outer support portions and a central support portion CL. The two outer support portions extend in one axial direction (the first axial direction herein) and are spaced apart from each other in another axial direction (the second axial direction herein), and the central support portion CL is disposed between the two outer support portions.

[0091] When the upper core 111 and the lower core 112 are coupled to each other in the vertical direction, each outer post and central post of the upper core 111 faces a corresponding outer post and central post of the lower core 112. In this case, a gap having a predetermined distance (e.g., 10 μm to 200 μm, but not necessarily limited thereto) can be formed between at least one pair of the facing outer posts and pairs of central posts. The gap can be a space defined between the spaced-apart upper core 111 and lower core 112, and the gap can be filled with air (i.e., an air gap) or it can be filled with an adhesive material.

[0092] In addition, core units 111 and 112 may include magnetic materials (such as iron or ferrite), but this disclosure is not necessarily limited thereto.

[0093] The first coil unit 120 may include a first coil frame B1 and a first coil C1. The first coil frame B1 has a first through hole CH1 (or a first cavity) formed in its center. The first coil C1 is wound around the first through hole CH1 in the receiving space of the first coil frame to form multiple turns.

[0094] The second coil unit 130 may include a second coil frame B2 and a second coil C2, the second coil frame B2 having a second through hole CH2 formed therein (see reference). Figure 4a (or a second cavity), the second coil C2 is disposed in the receiving space of the second coil frame B2 around the second through hole CH2 to form coil turns. Here, at least a portion of the first coil unit 120 may be disposed in the second through hole CH2. Therefore, at least a portion of the first coil unit 120 and at least a portion of the second coil unit 130 may overlap each other in the first axial direction and the second axial direction. Each of the first coil C1 and the second coil C2 may be a multi-turn winding in which a rigid metal (e.g., copper wire) is wound multiple times in a helical or planar helical shape, but this disclosure is not necessarily limited to this. For example, enameled wire (USTC wire), Litz wire, triple-insulated wire (TIW) wound with fiber yarn may be used for the first coil C1.

[0095] In some embodiments, the first coil unit 120 may correspond to the primary coil of the transformer 100, and the second coil unit 130 may correspond to the secondary coil of the transformer 100. However, this disclosure is not necessarily limited thereto.

[0096] Furthermore, the diameter of the second coil C2 may be 0.7 to 0.9 times the height of the second coil frame B2 in the third axis direction, but this disclosure is not necessarily limited to this.

[0097] Reference Figure 3a and Figure 3b The first coil unit 120 will be described in more detail, and reference will be made to... Figures 4a to 4c The second coil unit 130 is described in more detail.

[0098] With the first coil unit 120 and the second coil unit 130 coupled to each other, a terminal coil holder 140 is coupled to it and oriented in a first axial direction, and the terminal coil is provided with a terminal through which the first coil C1 is electrically connected to an external circuit (not shown). (Refer to later...) Figure 5a and Figure 5b The detailed construction of the terminal coil holder 140 is described in more detail.

[0099] A core fixing unit 150 is provided to ensure stable coupling between the upper core 111 and the lower core 112. The core fixing unit can be implemented by wrapping a polymer resin strip around the outer surface of the core unit 110 at least once in the second and third axial directions, but this disclosure is not necessarily limited to this.

[0100] Figure 3a This is a perspective view of the first coil frame according to this embodiment. Figure 3b This is a plan view of the first coil frame according to this embodiment.

[0101] Reference Figure 3a and Figure 3b According to the embodiment, the first coil frame B1 may include a first top plate TP1, a first bottom plate BP1, and a first sidewall SW1 disposed between the first top plate TP1 and the first bottom plate BP1. The first sidewall SW1 may define a first cavity CH1, and together with the lower surface of the first top plate TP1 and the upper surface of the first bottom plate BP1, may define a receiving space for receiving the first coil C1.

[0102] The first top plate TP1 may have a first lead-out slot DH1 and a second lead-out slot DH2, which are formed in the edge of the portion of the first top plate coupled to the terminal coil holder 140 in the first axial direction. One end of the two ends of the wire constituting the first coil C1 can be led upward through the first lead-out slot DH1, and the remaining end of the first coil C1 can be led upward through the second lead-out slot DH2. The two ends of the first coil C1 led out through the first lead-out slot DH1 and the second lead-out slot DH2 respectively can extend to the region above the terminal coil holder 140. Furthermore, the first lead-out slot DH1 and the second lead-out slot DH2 may overlap with the second recess RC2 in the terminal coil holder 140 in the third axial direction, which will be described later.

[0103] Figure 4a This is a plan view of the second coil frame according to this embodiment. Figure 4b This is a perspective view of the second coil frame according to this embodiment. Figure 4c This is a rear perspective view of the second coil frame according to this embodiment.

[0104] Reference Figures 4a to 4c According to the embodiment, the second coil frame B2 may include a second top plate TP2, a second bottom plate BP2, and a second sidewall SW2 disposed between the second top plate TP2 and the second bottom plate BP2. The second sidewall SW2 may define a second cavity CH2, and together with the lower surface of the second top plate TP2 and the upper surface of the second bottom plate BP2, may define a receiving space for receiving the second coil C2.

[0105] The first protruding portion PT1 and the second protruding portion PT2 that protrude upward in the third axial direction can be disposed on the portion of the second top plate TP2 that is coupled to the terminal coil frame 140 in the first axial direction, and the first partition wall portion PA1 that bends and extends upward in the third axial direction can be disposed on the edge of the portion of the second top plate TP2 that is opposite to the terminal coil frame 140 in the first axial direction.

[0106] A third protruding portion PT3, a fourth protruding portion PT4, a second partition wall portion PA2, a first support portion SP1, and a first recess RC1, all projecting downwards in the third axial direction, can be disposed on one of the plurality of portions of the second base plate BP2 oriented in the first axial direction. Furthermore, a plurality of second terminals TM2 and a second support portion SP2 can be disposed on opposite portions of the plurality of portions of the second base plate BP2 oriented in the first axial direction. The plurality of second terminals TM2 can be spaced apart from each other while being arranged parallel to each other in the second axial direction.

[0107] The first recess RC1 may have a planar shape, recessed at one end of the second base plate BP2 toward its opposite side. The width of the first recess RC1 in the second axial direction may gradually decrease from one end toward the opposite side. For example, the first recess RC1 may have a semi-circular or semi-elliptical planar shape, but this disclosure is not necessarily limited to this. A portion of the second coil C2 may be exposed through the first recess RC1, which will be referred to later. Figures 7d to 7f To describe in more detail.

[0108] The second partition wall portion PA2 can extend in the second axial direction, and the first support portion SP1 can protrude from the second partition wall portion PA2 toward the opposite side (i.e., the center of the second cavity CH2) in the first axial direction. The second support portion SP2 can protrude to one side in the first axial direction, and when the first coil unit 120 is inserted into the second cavity CH2 from top to bottom in the third axial direction, it can support the first coil unit 120 together with the first support portion SP1.

[0109] Simultaneously, when viewed in a plan view, a second wire guide WG2 can be disposed between the first partition wall portion PA1 and the plurality of terminals TM2. The second wire guide WG2 may include a central portion WG2_C and side portions WG2_S1 and WG2_S2. The central portion WG2_C may protrude from the second side wall portion SW2 toward the second terminal TM2, and its width in the second axial direction may gradually decrease toward the second terminal TM2. The side portions WG2_S1 and WG2_S2 may be plate-shaped and may be configured to connect the lower end of the first partition wall portion PA1 to the central portion WG2_C. For example, each of the side portions WG2_S1 and WG2_S2 may have an arcuate plane connecting the lower end of the first partition wall portion PA1 to the central portion WG2_C, and the second wire guide WG2 may have a T-shaped plane.

[0110] The second wire guide WG2 can be used to guide the innermost wire among the multiple wires constituting the second coil C2. Furthermore, the multiple wires constituting the second coil C2 (not shown) protrude upwards at the portions of the second top plate TP2 and the second bottom plate BP2 that do not overlap each other in the third axial direction (i.e., between the first partition wall portion PA1 and the second terminal TM2 when viewed in plan view). Therefore, the side portions WG2_S1 and WG2_S2 of the second wire guide WG2, together with the first partition wall portion PA1, can help ensure the insulation distance between the second coil C2 and the first coil C1, and between the second coil and the core unit 110.

[0111] The protruding parts PT1, PT2, PT3 and PT4 can be respectively fitted into the holes H1, H2, H3 and H4 in the terminal coil holder 140 (which will be described later), so that the second coil holder B2 and the terminal coil holder 140 are coupled and fixed to each other.

[0112] Figure 5a This is a plan view of the terminal coil frame according to this embodiment. Figure 5b This is a perspective view of the terminal coil frame according to this embodiment.

[0113] Let's refer to each other. Figure 5a and Figure 5b The terminal coil frame 140 may include a third top plate TP3, a third bottom plate BP3, and a third side wall SW3 disposed between the third top plate TP3 and the third bottom plate BP3.

[0114] The first hole H1, the second hole H2, and the first wire guide WG1 can be set on the third top plate TP3, and the third hole H3 and the fourth hole H4 can be set in the third bottom plate BP3.

[0115] An opening OP is formed in the side of the terminal coil holder 140 without the third sidewall SW3, allowing the second coil unit 130 to be inserted therein in the first axial direction, and a plurality of first terminals TM1 are provided on the side of the terminal coil holder 140 opposite to the opening in the first axial direction. A second recess RC2 can be formed in the third top plate TP3 and the third bottom plate BP3 respectively, positioned above and below the opening OP in the third axial direction, and recessed toward opposite sides in the first axial direction. In this case, the second recess formed in the third top plate TP3 and the second recess formed in the third bottom plate BP3 can have different planar shapes, but this disclosure is not necessarily limited to this. The planar shape of the second recess RC2 can preferably be configured such that the terminal coil holder 140 coupled to the first coil unit 120 and the second coil unit 130 does not obscure the first coil unit 120 (i.e., does not overlap with the first coil unit 120 in the third axial direction) or obscures only the minimum required portion of the first coil unit 120. This is done to prevent the heat generated from the first coil C1 of the first coil unit 120 from being trapped by the terminal coil holder 140.

[0116] Each of the plurality of first wire guides WG1 can extend from the second recess RC2 toward a corresponding one of the first terminals TM1. The number of first terminals TM1 and the number of first wire guides WG1 may be the same, but this disclosure is not necessarily limited thereto. One end of the first coil C1 can be led out through either the lead-out slots DH1 and DH2 in the first coil holder B1, and can be exposed upward through the second recess RC2 formed in the third top plate TP3. The exposed end of the first coil C1 can extend along the first wire guide WG1 toward the first terminal TM1 and can be electrically connected to the first terminal TM1.

[0117] Each of the plurality of first terminals TM1 can be implemented as a terminal pin TP, which extends in a first axial direction and bends in a third axial direction. The portion of the terminal pin TP extending in the first axial direction can be electrically connected and fixed to one end of the first coil C1 by soldering, and the portion of the terminal pin TP extending in the third axial direction can extend downward through the terminal coil holder 140 in the third axial direction to protrude downward from the terminal coil holder 140. The portion protruding downward from the terminal coil holder 140 can be electrically connected and fixed to a circuit board. The construction of the first terminal TM1 using the terminal pin TP can also be applied to the second terminal TM2.

[0118] In addition to the core fixing unit 150 described above, the transformer 100 according to the embodiment may include multiple adhesive portions to ensure higher reliability. This will be referred to Figure 6 Describe it.

[0119] Figure 6 An example of a transformer with an adhesive portion configured according to this embodiment is shown.

[0120] Reference Figure 6 First to third adhesive portions AD1, AD2 and AD3 may be provided between the first top plate TP1 of the first coil frame B1 of the first coil unit 120 and the open surface of the core unit 110, thereby allowing the core unit 110 and the first coil unit 120 to be more firmly coupled to each other.

[0121] Furthermore, a fourth adhesive portion AD4 may be provided between the second recess RC2 and the first top plate TP1 in the terminal coil holder 140.

[0122] Furthermore, the fifth adhesive portion AD5 and the sixth adhesive portion AD6 can be configured to extend along the contact line between the first coil unit 120 and the second coil unit 130 in the first axial direction. Of course, the fifth adhesive portion AD5 and the sixth adhesive portion AD6 can contact the lower surface of the body portion of the upper core 111 or the upper surface of the body portion of the lower core 112, as well as the contact line between the first coil unit 120 and the second coil unit 130.

[0123] Each adhesive portion may be an adhesive resin, but this disclosure is not necessarily limited thereto. Furthermore, although not shown, adhesive portions may also be formed on the coupling portions between the first to fourth protrusions PT1, PT2, PT3 and PT4 and the first to fourth holes H1, H2, H3 and H4.

[0124] In the following text, reference will be made to Figures 7a to 7g The arrangement of the second coil C2 according to the embodiment is described in more detail.

[0125] Figure 7a An example of setting up a coil for a second coil unit according to an embodiment is shown.

[0126] For ease of explanation, although the second coil C2 is in Figure 7a The second coil is shown as being mounted on the second coil frame B2, but it should be noted that the second coil C2 is actually mounted between the second top plate TP2 and the second bottom plate BP2 of the second coil frame B2.

[0127] Reference Figure 7a The second coil frame B2 may include: a central portion CP; a first portion 1P; located on one side of the central portion CP or the second through hole CH2 in the first axial direction; and a second portion 2P located on the other side of the central portion CP or the second through hole CH2 in the first axial direction opposite to the first portion 1P.

[0128] The second through hole CH2 can be disposed in the central portion CP, and the multiple terminal pins T1, T2, T3, T4, T5, T6, T7 and T8 constituting the second terminal TM2 can be disposed parallel to each other on the first portion 1P in the second axial direction.

[0129] The second coil C2 may include multiple wires L1, L2, L3 and L4.

[0130] Each of the multiple conductors L1, L2, L3 and L4 may have two ends, each end being electrically connected to a corresponding one of the multiple terminal pins T1, T2, T3, T4, T5, T6, T7 and T8, and may form a turn around the second through hole CH2.

[0131] For example, the two ends of the first wire L1 are connected to the second terminal pin T2 and the fifth terminal pin T5, and the two ends of the third wire L3 are connected to the first terminal pin T1 and the sixth terminal pin T6, respectively. In addition, the two ends of the second wire L2 are connected to the fourth terminal pin T4 and the seventh terminal pin T7, respectively, and the two ends of the fourth wire L4 are connected to the third terminal pin T3 and the eighth terminal pin T8, respectively.

[0132] Simultaneously, the first conductor L1 and the third conductor L3 can intersect with the second conductor L2 and the fourth conductor L4 on the second portion 2P, thereby at least partially overlapping with the second conductor L2 and the fourth conductor L4 in the third axial direction. Furthermore, multiple conductors L1, L2, L3, and L4 can be arranged parallel to each other in the second axial direction on the central portion CP, and can extend in the first axial direction. Although in Figure 7a The diagram shows that the central portion CP does not overlap with each other in the third axis direction, but multiple conductors L1, L2, L3, and L4 can partially overlap each other in the third axis direction in the region adjacent to the second portion 2P. That is, one side of each of the multiple conductors L1, L2, L3, and L4 can extend to be positioned on the second portion 2P, and the other side can extend to have both ends positioned on the first portion 1P.

[0133] Due to the aforementioned construction of the second coil unit 130, the wires constituting the second coil C2 partially overlap each other on the second portion 2P. However, since each individual wire forms only one turn, it can be understood that the second coil C2 is wound into one layer.

[0134] From a circuit perspective, in order to achieve inductance matching between the parts that form the same turns, the connection structure of the terminal pins and intersection points on the second part 2P is established.

[0135] This will refer to Figure 7b and Figure 7c Describe it.

[0136] Figure 7b A pin diagram of the second coil unit according to an embodiment is shown. Figure 7c This is a circuit diagram of a transformer according to an implementation method.

[0137] Reference Figure 7b and Figure 7c First conductor L1 and third conductor L3 are connected in parallel to form the first turn portion NS2 of the first signal for the secondary coil unit of the transformer. Second conductor L2 and fourth conductor L4 form the second turn portion NS3 of the second signal for the second coil unit. In this case, first terminal pin T1 and second terminal pin T2 correspond to the input terminals of the first signal, and fifth terminal pin T5 and sixth terminal pin T6 correspond to the ground portion of the first signal. Furthermore, seventh terminal pin T7 and eighth terminal pin T8 correspond to the input terminals of the second signal, and fourth terminal pin T4 and third terminal pin T3 correspond to the ground portion of the second signal. Here, the ground portions of the signals can be electrically connected to each other to form a so-called center tap (CT) structure.

[0138] Return to reference Figure 7a Due to the aforementioned connection between the wires and the terminal pins, when viewed in a plan view, the first wire L1 and the third wire L3 (arranged in parallel to form the first turn portion NS2) are mirror images (symmetrical) of the second wire L2 and the fourth wire L4 (arranged in parallel to form the second turn portion NS3) in the first axial direction relative to the second through-hole CH2. Therefore, since the first turn portion NS2 and the second turn portion NS3 have substantially the same wire construction, the inductance variation caused by the length difference between the wires can be minimized, resulting in reduced heat generation due to current concentration.

[0139] Meanwhile, since the conductors intersect each other on the second portion 2P of the second coil frame B2, they can overlap each other in the third axial direction. Therefore, it is necessary to ensure that the height of the second sidewall SW2 of the second coil frame B2 is at least twice the thickness of the conductors to prevent deformation of the second coil frame B2 at the second portion 2P. However, ensuring the height of the second sidewall SW2 may result in an overall thickening of the second coil frame B2, which could increase the overall thickness of the transformer. This will be referred to... Figure 7d Describe it.

[0140] Figure 7d This is a view used to explain the overlapping pattern of the wires on the second portion of the second coil unit according to an embodiment. Figure 7d In order to better understand, wires L1, L2, L3 and L4 are shown as solid lines regardless of whether they overlap.

[0141] Reference Figure 7dBased on the overlapping pattern of paired multiple wires, multiple overlapping regions are generated on the second part 2P of the second coil unit. For example, a first region A1, a second region A2, a third region A3, and a fourth region A4 are generated on the second part 2P. In plan view, the third wire L3 and the fourth wire in the first region A1 overlap each other; in plan view, the first wire L1 and the fourth wire L4 in the second region A2 overlap each other; in plan view, the second wire L2 and the third wire L3 in the third region A3 overlap each other; and in plan view, the first wire and the second wire in the fourth region A4 overlap each other.

[0142] These regions A1, A2, A3, and A4 require a larger receiving space in the direction of the third axis than the rest of the regions.

[0143] Therefore, the first recess RC1 can be formed in the second coil frame B2 to prevent the thickness of the second coil frame B2 from increasing.

[0144] Figure 7e This is a rear view of the second coil unit according to this embodiment. Figure 7f Is Figure 7e When viewed from the upper part in the direction of the arrow Figure 7e The side view of the second coil unit shown.

[0145] Let's refer to each other. Figure 7e and Figure 7f A first recess RC1 with a semi-circular planar shape is formed in the second base plate BP2 of the second coil unit 130. Although the height h2 of the receiving space (i.e., the height of the second sidewall SW2) is less than twice the wire diameter D, as Figure 7f As shown, however, the presence of the first recess RC1 ensures sufficient space between the conductors without deforming the coil frame. Therefore, it prevents an increase in the thickness of the second coil frame B2.

[0146] Preferably, the maximum length h1 of the first recess RC1 in the first axial direction is greater than twice the diameter of each conductor (2). D), such as Figure 7d As shown. Furthermore, preferably, the first recess RC1 is formed at a location comprising at least a portion of each of four regions A1, A2, A3, and A4, the four regions A1, A2, A3, and A4 being accessible via... Figure 7d The concave portion RC1 is formed by overlapping the conductors shown. Furthermore, it is preferred that the planar area of ​​the first recess RC1 is 50% to 90% of the sum of the areas of the four regions A1, A2, A3, and A4 formed by overlapping the conductors, but this disclosure is not necessarily limited to this.

[0147] Furthermore, the first recess RC1 is in Figure 7eThe diagram shows a planar shape with a semicircle, but this is merely illustrative. The planar shape of the first recess is not limited to any particular shape (e.g., circular, track-shaped, or polygonal), as long as the shape can enclose at least a portion of each of the four regions A1, A2, A3, and A4 created by the overlap between the wires.

[0148] Figure 7g This is a plan view showing an example of the construction of a second coil frame according to another embodiment.

[0149] Besides the short-circuit components SP1, SPC, and SP2, according to Figure 7g The construction of the second coil frame B2 in another embodiment shown is the same as that described above. Figure 4a The construction of the second coil frame B2 is the same as described, so repeated descriptions will be omitted.

[0150] Reference Figure 7g The first terminal pin T1 and the second terminal pin T2, corresponding to the input terminal of the first signal, can be shorted through the first short-circuit portion SP1. Furthermore, the seventh terminal pin T7 and the eighth terminal pin T8, corresponding to the input terminal of the second signal, can be shorted through the second short-circuit portion SP2. Additionally, the third to sixth terminal pins T3, T4, T5, and T6, corresponding to the ground portion of the center tap structure, can be shorted through the center short-circuit portion SPC.

[0151] Here, each short-circuit section SP1, SP2, and SPC can be implemented by soldering. However, this is merely illustrative, and this disclosure is not necessarily limited thereto. Any of a variety of methods capable of short-circuiting the terminal pins can be used. For example, each of the short-circuit sections SP1, SP2, and SPC can be implemented by conductive clips, conductive pins, or a combination thereof, and soldering.

[0152] Despite Figure 7g In the diagram, the center-short-circuit section SPC is shown as a single unit that shorts all third to sixth terminal pins T3, T4, T5, and T6. However, according to another option, the center-short-circuit section SPC may include a first center-short-circuit section (not shown) for shorting the third terminal pin T3 and the fourth terminal pin T4, and a second center-short-circuit section (not shown) for shorting the fifth terminal pin T5 and the sixth terminal pin T6. In this case, the first center-short-circuit section (not shown) and the second center-short-circuit section (not shown) may not be electrically connected to each other in the transformer.

[0153] Meanwhile, as described above, the transformer 100 according to the embodiment can be configured as a circuit board (not shown), which together with other magnetic components (e.g., inductors) constitutes a power supply unit (PSU).

[0154] Figure 8a This is a perspective view of a transformer according to yet another embodiment. Figure 8b This is a plan view of a transformer according to yet another embodiment. Furthermore, Figure 9 This is an exploded perspective view of a transformer according to yet another embodiment. Figure 10 This is a perspective view of the first coil frame according to yet another embodiment. Furthermore, Figure 11 This is an exploded perspective view of a coil frame unit according to another embodiment.

[0155] Let's refer to each other. Figures 8a to 11 According to another embodiment, the transformer 101 may include a core unit 110, coil frame units B1 and B2, and terminals TM1 and TM2. The various components will be described in detail below.

[0156] Core units 111 and 112 can function as magnetic circuits and thus can be used as paths for magnetic flux. Core units 111 and 112 may include an upper core 111 located at an upper position and a lower core 112 located at a lower position. The two cores 111 and 112 can be formed symmetrically or asymmetrically with each other in the vertical direction. However, for ease of explanation, the following description assumes that the two cores are formed to be vertically symmetrical with each other.

[0157] Each of the upper core 111 and the lower core 112 may include a body portion and a plurality of support portions OL1-1, OL1-2, OL2-1, OL2-2, CL1, and CL2. The body portion has a flat plate shape, and the plurality of support portions protrude from the body portion in the thickness direction (i.e., the Z-axis direction) and extend in a predetermined direction. For example, the plurality of support portions OL1-1, OL1-2, and CL1 of the upper core 111 may include two outer support portions OL1-1 and OL1-2 and a central support portion CL1. When viewed in a plan view, the two outer support portions OL1-1 and OL1-2 extend in one axial direction (the Y-axis direction herein) and are spaced apart from each other in another axial direction (the X-axis direction herein), and a central support portion CL1 is disposed between the two outer support portions OL1-1 and OL1-2.

[0158] When the upper core 111 and the lower core 112 are coupled to each other in the vertical direction, each outer support OL1-1 and OL1-2 of the upper core 111 and the central support CL1 face one of the corresponding outer supports OL2-1 and OL2-2 and the central support CL2 of the lower core 112. The pair of outer supports OL1-1 and OL2-1 facing each other can be called the first outer support section, the other pair of outer supports OL1-2 and OL2-2 facing each other can be called the second outer support section, and the pair of central supports CL1 and CL2 facing each other can be called the central support section.

[0159] A gap with a predetermined distance (e.g., 10 μm to 200 μm, but not necessarily limited thereto) can be formed between at least one pair of facing outer pillars and one pair of facing central pillars. The size of the gap between a pair of central pillars and between each pair of facing outer pillars can be adjusted to control the inductance of the core unit 110, and the generated heat can be controlled by changing the number of gaps.

[0160] In addition, the core unit 110 may include a magnetic material (such as iron or ferrite), but this disclosure is not necessarily limited thereto.

[0161] Since the core unit 110 surrounds a portion of the outer periphery of the coil frame units B1 and B2, it can be seen that a portion of the first coil unit (not shown) and a portion of the second coil unit (not shown) (received in the coil frame units B1 and B2) are disposed inside the core unit 110.

[0162] Coil frame units B1 and B2 may include a first coil frame B1 and a second coil frame B2.

[0163] The first coil frame B1 and the second coil frame B2 may have a first through hole TH1 and a second through hole TH2 formed therein, respectively, and the central pillars CL1 and CL2 of the core unit 110 may be aligned to pass through the first through hole TH1 and the second through hole TH2.

[0164] At least a portion of the first coil frame B1 can be received in the second coil frame B2, and may include a first top portion 121, a first middle portion 123, and a first bottom portion 122.

[0165] Each of the first top portion 121 and the first bottom portion 122 may have a planar shape of a quadrilateral with rounded corners, but this disclosure is not necessarily limited thereto. In addition, the first bottom portion 122 may have a planar shape that extends further outward than the first top portion 121 in the direction in which the support portions are spaced apart from each other (i.e., the X-axis direction).

[0166] The first intermediate portion 123 may be vertically disposed between the first top portion 121 and the first bottom portion 122, and may electrically insulate the central support portion from the wires (not shown) constituting the first coil unit. The inner surface of the first intermediate portion 123 may define a first through hole TH1. Furthermore, the space defined by the lower surface of the first top portion 121, the outer surface of the first intermediate portion 122, and a portion of the upper surface of the first bottom portion may be used as a receiving space for receiving the wires constituting the first coil unit.

[0167] The second coil frame B2 may include a second top portion 131, a second middle portion 133, a second bottom portion 132, and plate support portions CBS1 and CBS2.

[0168] The second intermediate portion 133 can be vertically disposed between the second top portion 131 and the second bottom portion 132, and can electrically isolate the wires (not shown) constituting the second coil unit from the wires (not shown) constituting the first coil unit. Furthermore, the space defined by a portion of the lower surface of the second top portion 131, the outer surface of the second intermediate portion 133, and a portion of the upper surface of the second bottom portion can be used as a receiving space for receiving the wires constituting the second coil unit.

[0169] Furthermore, the plate support portions CBS1 and CBS2, spaced apart from each other along the long axis of the second bottom portion 132, can be used to support the transformer 101 when it is mounted on a circuit board (not shown) of a device (e.g., a PSU). A plurality of protrusions 136 can be formed among the plurality of plate support portions, near the second plate support portion CBS2 adjacent to the second terminal TM2, to protrude downwards, and are arranged to be spaced apart from each other while being parallel to each other in the y-axis direction. The protrusions 136, together with the second plate support portion CBS2, can support the transformer 101 on the plate and can also serve as conductors to guide the ends of the conductors constituting the second coil unit to the second terminal TM2, the ends of which are led out between the second top portion 131 and the second bottom portion 132.

[0170] A second through hole TH2 can be provided in the central portion of the second top portion 131, and terminals TM1 and TM2 can be provided on the respective ends of the second top portion 131 in the direction of its long axis. Terminals TM1 and TM2 can be used to fix the transformer 101 to the plate (not shown) of the power supply unit (PSU), and can be used as an electrical connection path between the first and second coil units (not shown) of the transformer 101 and the plate (not shown) of the power supply unit (PSU).

[0171] More specifically, the first terminal TM1 may include a plurality of pins spaced apart from each other, and either end of the wires constituting the first coil unit may be electrically connected to at least one of the plurality of pins. For example, some of the pins constituting the first terminal TM1 may be opposite to other pins along the x-axis and may be arranged parallel to each other along the y-axis, while other pins may be arranged parallel to each other along the y-axis.

[0172] The second terminal TM2 may include a plurality of pins arranged parallel to each other and spaced apart from each other along the x-axis, and either end of the wire constituting the second coil unit may be electrically connected to at least one of the pins.

[0173] The first guide 134 and the second guide 135 are disposed on the upper surface of the second top portion 131, so that they face each other in the long axis direction (i.e., the Y-axis direction) of the second coil frame B2 (the second through hole TH2 is located between the first guide 134 and the second guide 135), and extend in the short axis direction (i.e., the X-axis direction). Here, the first guide 134 may be disposed adjacent to the second terminal TM2, and the second guide may be disposed adjacent to the first terminal TM1. The upper core 111 may be located between the first guide 134 and the second guide 135, and may be used to fix the position of the upper core 111 and increase the insulation distance between the upper core 111 and the terminals TM1 and TM2.

[0174] Furthermore, a reinforcing pattern portion 136 may be provided between the first guide 134 and the second terminal TM2 on the upper surface of the second top portion 131. For example, the reinforcing pattern portion 136 may be formed such that patterns with F-shaped planes are arranged opposite to each other in the X-axis direction, but this disclosure is not necessarily limited to this. The stiffness of the second top portion 131 can be increased by the reinforcing pattern portion 136, thereby preventing its deformation. Due to the height difference between the reinforcing pattern portion 136 and the second top portion 131, a plurality of recesses H1 and H2 may be formed to extend in the X-axis direction and may be used to increase the insulation distance between the upper core 111 and the second terminal TM2.

[0175] When constructing transformer 101, at least a portion of the first coil frame B1 can be received in a recess RC, which is defined by the lower surface of the second top portion 131 and the inner surface of the second intermediate portion 133 of the second coil frame B2.

[0176] Furthermore, when the first coil frame B1 and the second coil frame B2 are coupled to each other, the upper surface of the first top portion 121 faces the lower surface of the second top portion 131, and the portion of the upper surface of the first bottom portion 122 that does not overlap with the first top portion 121 in the vertical direction (i.e., the outwardly extending portion) faces the lower surface of the second bottom portion 132.

[0177] Furthermore, in the coupled state, the coil lead-out portion 124 of the first top portion 121 can pass through the third through hole TH3 in the second top portion 131 and can be exposed upwards. With the help of the coil lead-out portion 124, the two ends of the wire constituting the first coil unit can be easily led out and fixed to the upper surface of the second top portion 131, and can be directly connected to the first terminal TM1.

[0178] Furthermore, on the upper surface of the first top portion 121 of the first coil holder B1, a protruding pin 125 is provided between the first through hole TH1 and the coil lead-out portion 124, thereby protruding upward and extending in the X-axis direction. When the first coil holder B1 and the second coil holder B2 are coupled to each other, the protruding pin 125 can be inserted into the blind hole BH formed in the lower surface of the second top portion 131 at a position corresponding to the second guide 135. Therefore, the first coil holder B1 and the second coil holder B2 can be coupled to each other more firmly and stably, and Figure 13a The cross section shown is in a coupled state.

[0179] Simultaneously, a construction could be considered for bonding the coil frame units B1 and B2 and the core unit 110 together to achieve a robust coupling between them. For example, such as... Figure 8b As shown, the first adhesive groups AD1, AD2, AD3, and AD4 can be disposed in a laterally joined manner between the outer support of the core unit 110 and the portions of the coil frames B1 and B2 extending from the receiving space in the core unit 110 in the Y-axis direction, thus being exposed. For example, the first adhesive groups AD1, AD2, AD3, and AD4 may or may not contact the coil frames B1 and B2. Preferably, the first adhesive groups AD1, AD2, AD3, and AD4 contact both the upper core 111 and the lower core 112, thereby securing the upper core 111 and the lower core 112 to each other.

[0180] Furthermore, a second adhesive group AD5 and AD6 can be provided between the lower surface of the upper core 111 (corresponding to the area between the central support and the outer support) and the upper surface of the second coil frame B2. By means of the aforementioned adhesive portions AD1, AD2, AD3, AD4, AD5, and AD6, vibrations caused by gaps between the coil frames B1 and B2 and the core unit 110 can be prevented. Here, the first adhesive group AD1, AD2, AD3, and AD4 and the second adhesive group AD5 and AD6 can be implemented as adhesives with the same composition, or they can be implemented as adhesives with different compositions. Preferably, the second adhesive group AD5 and AD6 are implemented as adhesive resins, but this disclosure is not necessarily limited to this.

[0181] Reference Figure 12 Describe the receiving state of each coil unit in the first and second coil units as received due to the aforementioned coupling structure of coil frame units B1 and B2.

[0182] Figure 12 The transformer according to this embodiment is along Figure 8b The sectional view taken by line B-B' in the figure.

[0183] Reference Figure 12Coil frames B1 and B2 are disposed between core unit 110 and coil units 120 and 130. More specifically, coil units 120 and 130 and coil frames B1 and B2 are partially disposed in a first space B1 and a second space SB2 within core unit 110. The first space SB1 and the second space SB2 may be spaced apart from each other in a direction that separates the support portions (i.e., the X-axis direction), with central support portions CL1 and CL2 between them, and may be formed such that a rectangular plane extends in the Y-axis direction. Furthermore, the first space SB1 may be located between the central support portions CL1 and CL2 and the outer support portions OL1-1 and OL2-1 located on one side of core unit 110, and the second space SB2 may be located between the central support portions CL1 and CL2 and the outer support portions OL1-2 and OL2-2 located on the opposite side of core unit 110.

[0184] The first coil frame B1 may have a first receiving portion RP1 for receiving the first coil unit 120 and a first extension portion EP1 extending from the first receiving portion RP1 toward the second coil frame B2. That is, the first receiving portion RP1 may correspond to a portion of the first top portion 121, the first middle portion 123, and a portion of the first bottom portion 122 other than the first extension portion EP1.

[0185] The second coil frame B2 may have a second receiving portion RP2 for receiving the second coil unit 130 and a second extending portion EP2 extending from the second receiving portion RP2 toward the first coil frame B1. That is, the second receiving portion RP2 may include a part of the second top portion 131, a second middle portion 133, and a second bottom portion 132, in addition to the second extending portion EP2.

[0186] Furthermore, the second receiving portion RP2 is disposed on the first extension portion EP1, and the first receiving portion RP1 is disposed below the second extension portion EP2. Therefore, the shortest distance h1 from the lower surface of the lower core 112 to the first coil unit 120 is different from the shortest distance h2 from the lower surface of the lower core 112 to the second coil unit 130. That is, the shortest distance h1 from the lower surface of the lower core 112 to the first coil unit 120 is shorter than the shortest distance h2 from the lower surface of the lower core 112 to the second coil unit 130. For example, the shortest distance h1 from the lower surface of the lower core 112 to the first coil unit 120 can be 0.3 to 0.7 times the shortest distance h2 from the lower surface of the lower core 112 to the second coil unit 130.

[0187] Furthermore, due to the aforementioned coupling structure of coil frame units B1 and B2, a portion of the first coil unit 120 and a portion of the second coil unit 130 overlap each other in the direction from the outer support portion located on one side toward the outer support portion located on the opposite side, and their remaining portions do not overlap each other. The first coil unit 120 and the second coil unit 130 may not overlap each other in the vertical direction.

[0188] At least a portion of the second coil unit 130 is disposed next to the first coil unit 120, and a portion of the second receiving portion RP2 (i.e., the second intermediate portion 133) is disposed horizontally between the first coil unit 120 and the second coil unit 130.

[0189] Each of the first coil unit 120 and the second coil unit 130 can be a multi-turn winding in which a rigid metal conductor (e.g., copper wire) is wound multiple times, but this disclosure is not necessarily limited thereto. Furthermore, the thickness of the wire constituting the second coil unit 130 can be 50% to 150% of the thickness of the wire constituting the first coil unit 120, but this disclosure is not necessarily limited thereto.

[0190] Simultaneously, insulating units 161 and 162 can be provided between the coil frames B1 and B2 and the corresponding outer support portions. Insulating units 161 and 162 can extend from a region on the upper surface of the second receiving portion RP2 to the outside of the second receiving portion RP2, then bend and extend to surround the outside of the second receiving portion RP2 and the first extension portion EP1, and then bend and extend to a region on the lower surface of the first extension portion EP1. Therefore, both the second coil unit 130 and the first coil unit 120 can be electrically insulated from the outer support portion of the core unit 110. Insulating units 161 and 162 can include materials with excellent insulating properties (e.g., ketones or polyimides), but this disclosure is not necessarily limited to this.

[0191] Due to the above structure, the insulation distance between the first coil unit 120 and the core unit 110 can be greatly increased. For example, if the second extension EP2 were not present, the first insulation distance PATH1, starting from the upper side of the first coil unit 120, would extend directly to the lower surface of the upper coil frame. However, due to the presence of the second extension EP2, the length of the first insulation distance PATH1 extending in the x-axis direction is equal to or longer than the length of the second extension. Furthermore, the length of the second insulation distance PATH2 extending from the lower side of the first coil unit 120 is equal to the sum of the length of the first extension EP1 in the x-axis direction and the lengths of each insulating unit 161 and 162 in the same direction.

[0192] In addition to the leakage inductance obtained through the shortest distance β between the first coil unit 120 and the second coil unit 130, additional leakage inductance can be ensured because the first receiving portion RP1 and the second receiving portion RP2 are misaligned in the horizontal direction.

[0193] In the following text, reference will be made to Figure 13a and Figure 13b Describes the cross-section of the portion not surrounded by the core unit 110.

[0194] Figure 13a The transformer according to another embodiment... Figure 8b The sectional view taken by line A-A' in the middle. Figure 13b yes Figure 13a Enlarged view of section C.

[0195] Let's refer to each other. Figure 13a and Figure 13b In the regions where coil frame units B1 and B2 are not surrounded by core unit 110, the first extension portion EP1 may not be provided in the first coil frame B1. Furthermore, in the regions where coil frame units B1 and B2 are not surrounded by core unit 110 (i.e., outside the first space SB1 and the second space SB2), the shortest distance α between the first coil unit 120 and the second coil unit 130 may be the same as or different from the shortest distance β between the first coil unit 120 and the second coil unit 130 in the regions where coil frame units B1 and B2 are surrounded by core unit 110.

[0196] Preferably, the shortest distance ratio (β / α) can be between 1 and 1.3. When the shortest distance ratio (β / α) is less than 1, the overall size of the transformer 101 increases, and the change in leakage inductance is not significant. On the other hand, when the shortest distance ratio (β / α) exceeds 1.3, the energy conversion efficiency of the transformer 101 decreases. However, when viewed in a plan view, a shortest distance ratio (β / α) within the above range is... Figure 8b The values ​​are determined when the cutting lines A-A' and B-B' intersect each other at the center of the central support section, and can vary according to the radius of curvature in the winding direction of each of the first intermediate section 123 and the second intermediate section 133.

[0197] In the following text, reference will be made to Figure 14 The construction of a transformer 101 and a circuit in which the transformer 101 can be mounted, according to an embodiment, is described.

[0198] Figure 14 An example of the circuit construction of the power supply unit of an electronic product is shown.

[0199] refer to Figure 14This diagram illustrates the circuit configuration of a power supply unit (PSU) for an electronic product (e.g., a flat-panel TV), including a square wave generator 210, a resonator 220, and a rectifier 230. Flat-panel TVs typically support not only a normal mode but also various other operating modes (e.g., low-power mode), and each operating mode needs to be implemented efficiently. Therefore, the resonator 220 is implemented as an LLC resonant converter. The LLC resonant converter includes a first inductor (Lr) 221, a second inductor (Lm) 222, and a capacitor (Cr) 223. The inductance (Lm) of the second inductor 222 can be considered as the inductance of the operating circuit. The resonant frequency varies depending on the operating frequency of the PSU, and the inductance (Lr) of the first inductor 221 and the capacitance (Cr) of the capacitor 223 are factors that determine the operating frequency. If the inductance (Lr) of the first inductor 221 and the capacitance (Cr) of the capacitor 223 are not set to appropriate values, the overall efficiency of the circuit may decrease, or the circuit may malfunction.

[0200] The inductance (L) value of the leakage inductance integrated transformer (e.g., transformer 101 according to this embodiment) corresponds to "Lm" in the resonator 220, and its leakage inductance (Lk) value corresponds to "Lr" in the resonator 220.

[0201] The required ratio (Lk / Lm) for the PSU of a regular flat-screen TV is 10% to 20%, but the "Lk" value of a traditional transformer is too low to meet the ratio requirement.

[0202] More specifically, the leakage inductance of the transformer can be obtained using Equation 1 below.

[0203] [Equation 1] In Equation 1, "Lk" represents leakage inductance, "k" represents coupling coefficient, and "Lm" represents transformer inductance. The coupling coefficient k can be obtained experimentally, and for example, using Equation 2 below.

[0204] [Equation 2] In Equation 2, “X” represents the gap ratio (specifically, the ratio of the spacing between the first coil unit and the second coil unit to the shortest distance between the outermost periphery of the first coil unit and the adjacent outer support portion of the outermost periphery of the first coil unit), which defines the space in which the second coil unit can be wound (for convenience, it will be referred to as “winding space” below).

[0205] More specifically, when both the first coil frame B1 and the second coil frame B2 are present, the shortest distance between the first coil unit 120 and the second coil unit 130 (i.e., β in FIG. 5) corresponds to the distance between the outermost periphery of the first coil unit 120 and the innermost periphery of the second coil unit 130. Furthermore, if only the first coil frame B1 is present, the maximum permissible distance between the second coil unit 130 and the first coil unit 120 within the winding space where the second coil unit 130 can exist corresponds to the shortest distance from the outermost periphery of the first coil unit 120 to its adjacent outer support portion (i.e., Figure 12 (d1 in the middle).

[0206] The leakage inductance of the transformer varies depending on the coupling coefficient, and the coupling coefficient is particularly affected by the shortest distance between the first coil unit 120 and the second coil unit 130 in the core unit 110.

[0207] However, the shortest distance β between the first coil unit 120 and the second coil unit 130 depends on the position of the innermost circumference of the second coil unit 130 within the winding space. When only the increase in the shortest distance β is considered, the number of turns of the second coil unit 130 is limited by the finite winding space. Furthermore, to increase the size of the winding space, the size of the core unit 110 needs to be increased, thus limiting the extent to which the size of the winding space can be increased.

[0208] Therefore, in this embodiment, leakage inductance can be ensured by controlling the gap ratio (i.e., the ratio of the shortest distance β between the first coil unit 120 and the second coil unit 130 to the shortest distance d2 from the outermost periphery of the first coil unit 120 to its adjacent outer support portion).

[0209] For example, the shortest distance β between the first coil unit 120 and the second coil unit 130 is preferably 0.1 to 0.3 times "d1". If this ratio is less than 0.1, LLC matching of the circuit board (e.g., PSU) with the transformer mounted may be lost, which may cause the operating frequency to rise, resulting in the inability to control the circuit board. If this ratio exceeds 0.3, the efficiency of the transformer 101 may decrease, and oscillations may occur on the circuit board. However, this example is given under the assumption of using a general-purpose PSU, and this disclosure is not necessarily limited to this, depending on the type of circuit with the transformer mounted.

[0210] Therefore, referring to Equations 1 and 2, leakage inductance is affected by the coupling coefficient k, and the coupling coefficient is affected by the distance between the first coil unit and the second coil unit and the overlapping area between them. In the transformer 101 according to this embodiment, the coupling coefficient is reduced by controlling the spacing between the first coil unit and the second coil unit in order to increase leakage inductance, and additional leakage inductance is ensured by making the receiving space of the first coil unit and the receiving space of the second coil unit offset from each other in the horizontal direction.

[0211] Therefore, due to the above-described coupling structure of the coil frame unit, the transformer according to this embodiment can be made thinner and a high Lk value can be ensured, thus making it suitable for constituting a power supply unit for a flat-panel TV.

[0212] According to the transformer 101 of the above embodiment, at least in the region where the coil frame units B1 and B2 are surrounded by the core unit 110, due to the coupling structure of the coil frame units B1 and B2, the second receiving portion RP2 is disposed on the first extension portion EP1, and the first receiving portion RP1 is disposed below the second extension portion EP2, so that the first receiving portion RP1 and the second receiving portion RP2 do not overlap each other at least partially in the horizontal direction. However, according to another embodiment, the space for receiving the first coil unit 120 and the space for receiving the second coil unit 130 can be parallel to each other.

[0213] While this disclosure has been specifically shown and described with reference to exemplary embodiments thereof, these embodiments are for illustrative purposes only and are not intended to limit the disclosure. It will be apparent to those skilled in the art that various changes in form and detail may be made without departing from the essential characteristics of the embodiments described herein. For example, various constructions set forth in the embodiments may be modified and applied. Furthermore, such modifications and applications should be construed as falling within the scope of this disclosure as defined by the appended claims.

[0214] Inventive Method

[0215] Various implementation methods have been described in the best manner for carrying out this disclosure.

Claims

1. A transformer, comprising: The core unit includes an upper core and a lower core; The first coil unit and the second coil unit are at least partially disposed between the upper core and the lower core; as well as The terminal coil holder is coupled to one side of the second coil unit in a first direction. The first coil unit includes: a first coil; and a first coil frame having a first through hole, the central support of the core unit passing through the first through hole, and the first coil frame receiving the first coil. The second coil unit includes: a second coil; and a second coil holder having a second through hole, the second through hole receiving at least a portion of the first coil unit, and the second coil holder receiving the second coil. The terminal coil holder includes: a plurality of first terminals spaced apart from each other in a second direction intersecting the first direction on one side of the terminal coil holder oriented along the first direction; and an opening formed in another side opposite to the first direction to allow one side of the second coil unit to be inserted therein. The two ends of the first coil are led out from the first coil holder and respectively connected to different first terminals among the plurality of first terminals of the terminal coil holder. The terminal coil holder includes a recess formed on the other side of the terminal coil holder oriented in the first direction, and the recess is configured to expose the first coil unit.

2. The transformer according to claim 1, wherein, The first coil frame includes: A first top plate; a first bottom plate, spaced apart from the first top plate in a third direction intersecting the first and second directions; and a first sidewall, disposed between the first top plate and the first bottom plate, and The first top plate includes: The lead-out slot allows the two ends to be led out to the first top plate through the lead-out slot.

3. The transformer according to claim 2, wherein, The recess overlaps with the lead-out groove in the third direction.

4. The transformer according to claim 3, wherein, The terminal coil frame includes a plurality of first wire guides, which extend from the recess toward the plurality of first terminals, and The two ends of the first coil are led out through the lead-out slot and extend to the corresponding first terminal along different first wire guides among the plurality of first wire guides.

5. The transformer according to claim 1, wherein, The second coil frame includes: A second top plate; a second bottom plate, spaced apart from the second top plate in a third direction intersecting the first and second directions; and a second side wall, disposed between the second top plate and the second bottom plate.

6. The transformer according to claim 5, comprising: The first part is disposed on one side of the second coil frame in the first direction relative to the second through hole; as well as The second part is disposed on the side opposite to the first part relative to the second through hole. The second coil includes multiple wires arranged around the second through hole. One side of one of the plurality of wires extends to be disposed on the second part. One side of one of the plurality of wires extends such that both ends of the other side of the plurality of wires are positioned on the first portion. Wherein, the first and second conductors of the plurality of conductors at least partially overlap each other in the second portion, and The second coil frame includes: The recess, in the third direction, at least partially overlaps with the area where the first and second conductors on the second portion overlap each other.

7. The transformer according to claim 6, wherein, The recess is formed in the second base plate.

8. The transformer according to claim 6, wherein, The second coil frame also includes a plurality of second terminals disposed on the second base plate in the first part.

9. The transformer according to claim 6, wherein, The first wire and the second wire have symmetrical shapes relative to the second through hole in the first direction.

10. The transformer according to claim 6, wherein, The plurality of conductors also includes: The third conductor, when viewed in a plan view, forms a turn outside the first conductor; and The fourth conductor forms a turn outside the second conductor when viewed in a plan view.

11. The transformer according to claim 10, wherein, The third conductor and the first conductor are arranged parallel to each other to form a turn, and The fourth conductor and the second conductor are arranged in parallel to form a turn.

12. The transformer according to claim 8, wherein, The second top plate includes a first partition wall portion that projects upward along the third direction from an edge of the first portion oriented in the first direction and extends in the second direction.

13. The transformer according to claim 12, wherein, The second coil frame further includes a second wire guide that extends along the first direction between the second sidewall and the plurality of second terminals.

14. The transformer according to claim 6, wherein, The second coil frame also includes: The second partition wall portion protrudes downward from the second base plate in the third direction between the second through hole and the recess, and extends in the second direction.

15. The transformer according to claim 14, wherein, The second coil frame also includes: A first support portion protrudes from the second partition wall portion toward the second through hole in the first direction; and The second support portion, facing the first support portion, has a second through hole located between the first support portion and the second support portion, and The first support portion and the second support portion support the first coil unit.

16. A transformer, comprising: The core unit includes an upper core and a lower core; The coil unit is partially disposed in the core unit; as well as A coil frame unit is disposed between the core unit and the coil unit. The coil unit includes: A first coil and a second coil at least partially disposed next to the first coil. The coil frame unit includes: A first coil frame, including a first receiving portion formed therein for receiving the first coil; and The second coil holder includes a second receiving portion formed therein for receiving the second coil. The first coil frame includes a first extension portion extending from the first receiving portion toward the second coil frame. The second receiving portion is disposed on the first extension portion, and An insulating unit is provided between the coil frame unit and the core unit, and the insulating unit surrounds the outside of the second receiving portion of the second coil frame and the first extension portion of the first coil.

17. The transformer according to claim 16, wherein, The first coil frame includes: First top section; The first bottom portion is located below the first top portion; and A first intermediate portion is disposed between the first top portion and the first bottom portion, the first intermediate portion including a first through hole defined by its inner surface, and The first extension portion is disposed on the first bottom portion.

18. The transformer according to claim 16, wherein, The second coil frame includes: The second top portion includes a second through hole formed in its central portion; The second bottom portion is located below the second top portion; and The second intermediate portion is disposed between the second top portion and the second bottom portion, and The first coil frame is at least partially received in a recess defined by the lower surface of the second top portion and the inner surface of the second intermediate portion.

19. The transformer according to claim 16, wherein, The shortest distance from the lower surface of the lower core to the first coil is different from the shortest distance from the lower surface of the lower core to the second coil.

20. The transformer according to claim 16, wherein, The core unit includes: The structure comprises a first outer support section, a second outer support section, and a central support section disposed between the first outer support section and the second outer support section. The shortest distance between the first coil and the second coil is 0.1 to 0.3 times the shortest distance from the outermost periphery of the first coil to the shortest distance from the outermost support portion of the first outer support portion to the outermost support portion of the second outer support portion adjacent to the outermost periphery of the first coil.

21. A circuit board, comprising: substrate; and The transformer is mounted on the base plate. The transformer includes: The core unit includes an upper core and a lower core; The first coil unit and the second coil unit are at least partially disposed between the upper core and the lower core; and The terminal coil holder is coupled to one side of the second coil unit in a first direction. The first coil unit includes a first coil and a first coil frame with a first through hole. The central support of the core unit passes through the first through hole, and the first coil frame receives the first coil. The second coil unit includes a second coil and a second coil holder having a second through hole for receiving at least a portion of the first coil unit, the second coil holder receiving the second coil. The terminal coil holder includes: a plurality of first terminals spaced apart from each other in a second direction intersecting the first direction on one side of the terminal coil holder oriented along the first direction; and an opening formed on another side opposite to the first direction to allow one side of the second coil unit to be inserted therein. The two ends of the first coil are led out from the first coil holder and respectively connected to different first terminals among the plurality of first terminals of the terminal coil holder. The terminal coil holder includes a recess formed on the other side of the terminal coil holder oriented in the first direction, and the recess is configured to expose the first coil unit.

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