Resonant transformer

Abstract

The present invention discloses a resonant transformer with a vertical structure design to reduce eddy current loss. In particular, the present invention adopts a two-piece structure design for the slot-type winding frame used to wind coils, which facilitates modular design and assembly. The resonant transformer of the present invention mainly comprises a first core, a second core, a first winding frame, a second winding frame, a first terminal block, and a second terminal block, wherein the first winding frame (referred to as a child sleeve) has a secondary winding wound thereon, and the second winding frame (referred to as a mother sleeve) has a primary winding wound thereon. Further, the present invention also designs a cover to be sleeved with the mother sleeve to isolate the primary winding on the mother sleeve and the secondary winding on the child sleeve by using the cover. According to this design, the resonant transformer of the present invention allows the corresponding child sleeve to be replaced to meet different application requirements (such as: large current output or small current output).

Description

Technical Field

[0001] This invention relates to the field of power electronics, and more particularly to a resonant transformer used in power conversion devices. Background Technology

[0002] With the evolution and development of electronic products, different electronic products require different voltages to drive them; therefore, power supply manufacturers are actively trying to develop various suitable transformers for use in corresponding power supply devices. Currently, there are two types of resonant transformers with primary inductance and leakage inductance. The first type uses a primary transformer combined with a resonant inductor to generate and adjust the leakage inductance through the resonant inductor. However, this option requires both a primary transformer and a resonant inductor, thus requiring a large space and hindering miniaturization design. The second type is a slotted transformer, which has two sets of windings to generate the primary magnetic path and the leakage magnetic path respectively. The two windings are separated from each other, and the number of turns of the coils is adjusted to control the leakage inductance value.

[0003] Therefore, slotted transformers have become the mainstream type of resonant transformer. Conventional technology designs resonant transformers with a vertical structure, arranging the primary and secondary leads on opposite sides of a slotted winding frame. However, with the thinning of vertical resonant transformers (i.e., reduction in height), triple-insulated wire must be used as coils wound on the slotted winding frame to form the primary and secondary windings, increasing the manufacturing cost of the resonant transformer. Furthermore, the conventional slotted winding frame has a fixed size and cannot be adaptively adjusted or changed according to application requirements, limiting the application of conventional resonant transformers to specific power conversion devices.

[0004] As can be seen from the foregoing description, conventional vertical resonant transformers still have aspects in their structural design that require improvement. In view of this, the inventors of this invention have diligently researched and developed a resonant transformer according to the present invention. Summary of the Invention

[0005] The main objective of this invention is to provide a resonant transformer with a vertical structural design to reduce eddy current losses. Specifically, this invention adopts a two-piece structure design for the slotted winding frame used to wind the coils, facilitating modular design and assembly. The resonant transformer of this invention mainly includes: a first core, a second core, a first winding frame, a second winding frame, a first terminal block, and a second terminal block. The first winding frame (referred to as the "sub-frame") has a primary winding wound on it, and the second winding frame (referred to as the "mother frame") has a primary winding wound on it. Furthermore, this invention also designs a cover for housing the mother frame, thereby isolating the primary winding on the mother frame from the secondary winding on the sub-frame. With this design, the resonant transformer of this invention allows for the replacement of the corresponding sub-frames to meet different application requirements (e.g., high current output or low current output).

[0006] To achieve the above objectives, the present invention provides an embodiment of the resonant transformer, which includes:

[0007] First iron core;

[0008] The first winding frame has a first tube, a first plate connected to one end of the first tube, and a second plate connected to the other end of the first tube, wherein a primary winding is wound on the first tube, and the first plate is disposed on the first iron core.

[0009] A first terminal block is formed on one side of the first plate and has a plurality of first terminals;

[0010] The second winding frame is disposed on the first winding frame and has a second tube, a third plate connected to one end of the second tube, and a fourth plate connected to the other end of the second tube, wherein a primary winding is wound on the second tube.

[0011] The second terminal block is formed on one side of the third plate and has a plurality of second terminals;

[0012] The support structure includes a left support member and a right support member, wherein the left support member and the right support member are arranged along the two sides of the third plate and one end of the support member is connected to the second terminal block.

[0013] The cover, fitted onto the second winding frame to partially cover the third and fourth plates, is supported by the support structure; and

[0014] The second iron core is installed on the fourth plate.

[0015] In one embodiment, the second terminal is a straight terminal, and the first terminal is selected from any of the group consisting of straight terminals and L-shaped terminals.

[0016] In one embodiment, the first iron core is an E-shaped iron core, the first tube has a first hollow portion, the first plate has a first opening communicating with the first hollow portion, the second plate has a second opening communicating with the first hollow portion, and the first middle portion of the first iron core passes through the first opening into the first hollow portion.

[0017] In one embodiment, the second iron core is also an E-shaped iron core, the second tube has a second hollow portion, the third plate has a third opening communicating with the second hollow portion, the fourth plate has a fourth opening communicating with the second hollow portion, and the second middle portion of the second iron core passes through the fourth opening into the second hollow portion.

[0018] In one embodiment, there is a left gap between the left support member and the left side of the third plate, and a right gap between the right support member and the right side of the third plate. The third plate is stacked on the second plate through the left support member and the right support member, such that the first hollow portion of the second tube is coaxial with the second hollow portion of the first tube.

[0019] In one embodiment, the bottom surface of the third plate has a setting area for a magnetic element to be disposed therein, and the magnetic element is used to adjust the leakage inductance of the resonant transformer.

[0020] In one embodiment, the cover is a U-shaped cover formed by a U-shaped middle plate, a U-shaped upper plate, and a U-shaped lower plate.

[0021] In one embodiment, when connected to the second winding frame, the left part of the U-shaped lower plate is partially embedded in the left gap, the right part of the U-shaped lower plate is partially embedded in the right gap, and the lower surface of the U-shaped upper plate faces the upper surface of the fourth plate.

[0022] In one embodiment, the lower surface of the first plate is provided with two first limiting members, and there is a limiting space between the two first limiting members, so that the first iron core is limited within the limiting space.

[0023] In one embodiment, the upper surface of the fourth plate is provided with two second limiting members, and there is also a limiting space between the two second limiting members, so that the second iron core is limited within the limiting space. Attached Figure Description

[0024] Figure 1 This is a first perspective view of a resonant transformer according to the present invention;

[0025] Figure 2 This is a second perspective view of the resonant transformer of the present invention;

[0026] Figure 3 This is a first exploded perspective view of the resonant transformer of the present invention;

[0027] Figure 4 This is a second exploded perspective view of the resonant transformer of the present invention;

[0028] Figure 5 This is a perspective view of the first winding frame, first terminal block, second winding frame, second terminal block, and support structure of the resonant transformer of the present invention; and

[0029] Figure 6 This is a cross-sectional view of the resonant voltage converter of the present invention.

[0030] Explanation of reference numerals in the attached figures:

[0031] 1: Resonant Transformer

[0032] 11: First Iron Core

[0033] 11C: First intermediate part

[0034] 12: First winding frame

[0035] 121: First fitting

[0036] 122: First Slab

[0037] 1221: First Opening

[0038] 122L: First limiting component

[0039] 123: Second plate

[0040] 1231: Second opening

[0041] 13: First terminal block

[0042] 131: First terminal

[0043] 14: Second winding frame

[0044] 141: Second fitting

[0045] 142: Third plate

[0046] 1421: Third opening

[0047] 142R: Settings Area

[0048] 143: Fourth Plate

[0049] 1431: Fourth Opening

[0050] 143L: Second limiting component

[0051] 15: Second terminal block

[0052] 151: Second terminal

[0053] 16: Supporting Structure

[0054] 17: Cover

[0055] 17B: U-shaped intermediate plate

[0056] 17U: U-shaped upper plate

[0057] 17L: U-shaped lower plate

[0058] 18: Second iron core

[0059] 18C: Second intermediate part

[0060] 19: Magnetic components Detailed Implementation

[0061] To more clearly describe the resonant transformer proposed in this invention, the preferred embodiments of the invention will be described in detail below with reference to the accompanying drawings.

[0062] Figure 1 and Figure 2 These are first and second perspective views of a resonant transformer according to the present invention. Furthermore, Figure 3 and Figure 4 These are the first and second exploded perspective views of the resonant transformer of the present invention. Figures 1-4 As shown, this invention proposes a resonant transformer 1 with a vertical structure design, which mainly includes: a first iron core 11, a first winding frame 12, a first terminal block 13, a second winding frame 14, a second terminal block 15, a support structure 16, a cover 17, and a second iron core 18. According to the design of this invention, the first winding frame 12 (which can be referred to as the sub-frame) has a first tube 121, a first plate 122 connected to one end of the first tube 121, and a second plate 123 connected to the other end of the first tube 121. Figure 3 and Figure 4 It is understood that the first winding frame 12 is disposed on the first iron core 11 with its first plate 122. Furthermore, a secondary winding is wound on the first tube 121, and the first terminal block 13 is formed on one side of the first plate 122, having a plurality of first terminals 131. Depending on the application, the first terminals 131 can be straight terminals or L-shaped terminals. More specifically, the straight-designed first terminals 131 are used for 12V output, while the L-shaped first terminals 131 are used for 24V output.

[0063] Furthermore, Figure 5 This view shows a perspective view of the first winding frame 12, the first terminal block 13, the second winding frame 14, the second terminal block 15, and the support structure 16. Furthermore, Figure 6 This is a cross-sectional view of the resonant voltage transformer 1 of the present invention. Figures 3-6As shown, the first iron core 11 is an E-shaped iron core, the first tube 121 has a first hollow portion, the first plate 122 has a first opening 1221 communicating with the first hollow portion, the second plate 123 has a second opening 1231 communicating with the first hollow portion, and the first middle portion 11C of the first iron core 11 passes through the first opening 1221 into the first hollow portion.

[0064] In more detail, the second winding frame 14 (which may be referred to as the female sleeve) is mounted on the first winding frame 12 and has a second tube 141, a third plate 142 connected to one end of the second tube 141, and a fourth plate 143 connected to the other end of the second tube 141. A primary winding is wound on the second tube 141, and a second terminal block 15 is formed on one side of the third plate 142, having a plurality of second terminals 151, which are linear terminals. It is worth noting that the second iron core 18 is mounted on the fourth plate 143. Figure 3 , Figure 4 and Figure 6 As shown, the second iron core 18 is also an E-shaped iron core, the second tube 141 has a second hollow portion, the third plate 142 has a third opening 1421 communicating with the second hollow portion, the fourth plate 143 has a fourth opening 1431 communicating with the second hollow portion, and the second middle portion 18C of the second iron core 18 passes through the fourth opening 1431 into the second hollow portion.

[0065] Specifically, the present invention includes a support structure 16 comprising a left support member and a right support member. For example... Figure 3 , Figure 4 and Figure 5 As shown, the left and right support members are arranged along the two sides of the third plate 142, and one end of each is connected to the second terminal block 15. Furthermore, there is a left gap between the left support member and the left side of the third plate 142, and a right gap between the right support member and the right side of the third plate 142. The third plate 142 is superimposed on the second plate 123 through the left and right support members, such that the first hollow portion of the second tube 141 is coaxial with the second hollow portion of the first tube 121. This design also simultaneously confines the second plate 123 between the left and right support members of the support structure 16.

[0066] Furthermore, the present invention also designs a cover 17 for housing the female sleeve (i.e., the second winding frame 14), so as to use the cover 17 to isolate the primary winding wound on the second tube 141 of the second winding frame 14 and the secondary winding wound on the first tube 121 of the first winding frame 12. Figures 3-6As shown, the cover 17, fitted onto the second winding frame 14, partially covers the third plate 142 and the fourth plate 143, and is supported by the support structure 16. In one embodiment, the cover 17 is a U-shaped cover 17 formed by a U-shaped middle plate 17B, a U-shaped upper plate 17U, and a U-shaped lower plate 17L. With this design, when connected to the second winding frame 14 (i.e., the female sleeve), a left portion of the U-shaped lower plate 17L is partially embedded in the left gap, a right portion of the U-shaped lower plate 17L is partially embedded in the right gap, and the lower surface of the U-shaped upper plate 17U faces the upper surface of the fourth plate 143.

[0067] It should be noted that, for example Figure 3 and Figure 4 As shown, the lower surface of the first plate 122 is provided with two first limiting members 122L, and a limiting space is formed between the two first limiting members 122L, so that the first iron core 11 is limited within the limiting space. On the other hand, the upper surface of the fourth plate 143 is provided with two second limiting members 143L, and a limiting space is also formed between the two second limiting members 143L, so that the second iron core 18 is limited within the limiting space. Furthermore, in order to enable the resonant transformer 1 to have an adjustable leakage flux (Lm), the present invention further provides a setting area 142R on the bottom surface of the third plate 142 of the second winding frame 14 (i.e., the female sleeve). When it is necessary to increase the leakage flux, a magnetic member 19 can be set in the setting area 142R, thereby increasing the leakage inductance of the resonant transformer 1. For example, when the resonant transformer 1 of the present invention is used in a low-power LLC power conversion device, the leakage inductance of the resonant transformer 1 can be doubled by adding the magnetic element 19. On the other hand, when the resonant transformer 1 of the present invention is used in a relatively high-power LLC power conversion device, the magnetic element 19 is not required.

[0068] Thus, the resonant transformer of the present invention has been fully and clearly described above; and, as can be seen from the above, the present invention has the following advantages:

[0069] (1) The present invention adopts a vertical structure design for the resonant transformer 1 to reduce eddy current losses. Furthermore, the present invention adopts a two-piece design of a slotted winding frame for winding the coil, consisting of a mother sleeve and a daughter sleeve, to facilitate modular design and assembly. Based on this design, the resonant transformer 1 of the present invention allows for the replacement of corresponding daughter sleeves to meet different application requirements (e.g., high current output or low current output).

[0070] (2) The present invention also designs a cover 17 for housing the female sleeve, so as to isolate the primary winding on the female sleeve and the secondary winding on the female sleeve, thereby meeting the regulatory requirements for distance. According to this design, it is possible to use ordinary enameled wire to wind the primary winding and secondary winding on the female sleeve and the female sleeve respectively, without the need to use high-cost triple-insulated wire.

[0071] However, it must be emphasized that the above detailed description is a specific description of feasible embodiments of the present invention, but such embodiments are not intended to limit the patent scope of the present invention. All equivalent implementations or modifications that do not depart from the spirit of the present invention should be included in the patent scope of this case.

Claims

1. A resonant transformer, characterized in that, include: First iron core; The first winding frame has a first tube, a first plate connected to one end of the first tube, and a second plate connected to the other end of the first tube, wherein a primary winding is wound on the first tube, and the first plate is disposed on the first iron core. A first terminal block is formed on one side of the first plate and has a plurality of first terminals; The second winding frame is disposed on the first winding frame and has a second tube, a third plate connected to one end of the second tube, and a fourth plate connected to the other end of the second tube, wherein a primary winding is wound on the second tube. The second terminal block is formed on one side of the third plate and has a plurality of second terminals; The support structure includes a left support member and a right support member, wherein the left support member and the right support member are arranged along the two sides of the third plate and one end of the support member is connected to the second terminal block. The cover, fitted onto the second winding frame to partially cover the third and fourth plates, is supported by the support structure; and The second iron core is mounted on the fourth plate. There is a left gap between the left support member and the left side of the third plate, and a right gap between the right support member and the right side of the third plate. The third plate is stacked on the second plate through the left support member and the right support member. The bottom surface of the third plate has a mounting area for a magnetic component to be mounted therein, and the magnetic component is located between the primary winding and the secondary winding to adjust the leakage inductance of the resonant transformer.

2. The resonant transformer according to claim 1, characterized in that, The second terminal is a straight terminal, and the first terminal is selected from any one of the groups consisting of straight terminals and L-shaped terminals.

3. The resonant transformer according to claim 1, characterized in that, The first iron core is an E-shaped iron core. The first tube has a first hollow portion. The first plate has a first opening that communicates with the first hollow portion. The second plate has a second opening that communicates with the first hollow portion. A first middle portion of the first iron core passes through the first opening into the first hollow portion.

4. The resonant transformer according to claim 3, characterized in that, The second iron core is also an E-shaped iron core. The second tube has a second hollow portion. The third plate has a third opening that connects to the second hollow portion. The fourth plate has a fourth opening that connects to the second hollow portion. The second middle portion of the second iron core passes through the fourth opening into the second hollow portion.

5. The resonant transformer according to claim 1, characterized in that, The enclosure is a U-shaped enclosure formed by a U-shaped middle plate, a U-shaped upper plate, and a U-shaped lower plate.

6. The resonant transformer according to claim 5, characterized in that, When connected to the second winding frame, the left part of the U-shaped lower plate is partially embedded in the left gap, the right part of the U-shaped lower plate is partially embedded in the right gap, and the lower surface of the U-shaped upper plate faces the upper surface of the fourth plate.

7. The resonant transformer according to claim 4, characterized in that, The lower surface of the first plate is provided with two first limiting members, and there is a limiting space between the two first limiting members, so that the first iron core is limited within the limiting space.

8. The resonant transformer according to claim 7, characterized in that, The upper surface of the fourth plate is provided with two second limiting members, and there is also a limiting space between the two second limiting members, so that the second iron core is limited within the limiting space.

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