Switching power supply and computing device

Abstract

The embodiment of the application relates to the technical field of power supply, in particular to a switching power supply and a computing device. The switching power supply comprises a circuit board and a transformer; wherein the transformer comprises a PCB winding, a coil assembly and a magnetic core; the PCB winding is arranged in the circuit board; the coil assembly is arranged on the circuit board; wherein the alternating current resistance (ACR) of the coil in the coil assembly is less than the ACR of the PCB winding; the magnetic core is carried on the circuit board and penetrates through the PCB winding and the coil; wherein the PCB winding is used as one of a primary side and a secondary side of the transformer; and the coil is used as the other one of the primary side and the secondary side of the transformer. The switching power supply can be prepared in an automatic mode, and the efficiency of the power supply can be improved.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 202211500381.0, filed with the Chinese Patent Office on November 28, 2022, entitled "Switching Power Supply and Computing Device", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of power supply technology, and in particular to a switching power supply and a computing device. Background Technology

[0003] With the development of power electronics technology, the power density of switching power supplies is increasing, their size is decreasing, and their output power is increasing. Furthermore, energy efficiency standards are placing increasingly stringent requirements on the power efficiency of switching power supplies.

[0004] Current switching power supplies either fail to meet the requirements for power density and / or power efficiency, or their manufacturing processes are complex. Therefore, there is a need for switching power supplies that can meet both power density and power efficiency requirements while being easy to manufacture. Summary of the Invention

[0005] This application provides a switching power supply and a computing device, which can be assembled and manufactured in an automated manner.

[0006] In a first aspect, a switching power supply is provided, comprising: a circuit board and a transformer; the transformer includes a PCB winding, a coil assembly, and a magnetic core; the circuit board has a first through hole; the PCB winding is disposed within the circuit board around the first through hole; the coil assembly is disposed above the circuit board, and the coil assembly includes a coil, a carrier plate, a first connector, and a second connector; the carrier plate includes a first surface and a second surface disposed opposite to each other; the second surface faces the circuit board; the carrier plate has a second through hole, and the coil is fixed to the first surface of the carrier plate around the second through hole; the first connector and the second connector are at least partially disposed on the second surface of the carrier plate; the first connector and the second connector respectively include a first end and a second end; wherein, the first end of the first connector is electrically connected to one end of the coil, and the second end is electrically connected to the circuit board; the first end of the second connector is electrically connected to the other end of the coil, and the second end is electrically connected to the circuit board; the first through hole and the second through hole are disposed opposite to each other; the magnetic core includes a central post; the central post passes through the first through hole and the second through hole.

[0007] In this switching power supply, a coil assembly is used. The coil is mounted onto the circuit board via a carrier plate, so that the coil, the PCB windings on the circuit board, and the magnetic core constitute a transformer, enabling automated transformer assembly. Specifically, the coil is fixed on the carrier plate, which can be operated by automated equipment. The automated equipment operates the carrier plate to assemble the coil onto the circuit board, thereby achieving automated coil assembly.

[0008] In one possible implementation, the coil is wound with Litz wire. By using Litz wire, the AC resistance of the coil is reduced, thereby reducing transformer losses.

[0009] In this switching power supply, a coil is used as the primary side of the transformer, which reduces the primary side loss and improves the efficiency of the switching power supply compared to a transformer where both the primary and secondary sides are PCB windings.

[0010] In summary, the switching power supply provided in this application embodiment improves power supply efficiency while achieving automated assembly, thereby increasing the production efficiency of the switching power supply.

[0011] In one possible implementation, the support plate includes two connecting through holes; a first connector passes through the support plate through one connecting through hole; a second connector passes through the support plate through the other connecting through hole; wherein, the first end of the first connector and the first end of the second connector protrude from the first surface of the support plate; the second end of the first connector and the second end of the second connector protrude from the second surface of the support plate.

[0012] In this embodiment, the connector penetrates through the carrier plate, with one end protruding from the first surface connected to the coil and the other end protruding from the second surface used to connect to the circuit board. This allows the circuit board and the coil to be easily connected together, improving the manufacturing efficiency of the switching power supply.

[0013] In one possible implementation, the carrier includes a first side and a second side disposed opposite to each other; the first side and the second side are located between the first surface and the second surface; wherein the first side of the carrier plate is close to the lead end of the coil, and the second side of the carrier plate is far from the lead end of the coil; a first connector covers a portion of the first surface, the first side of the carrier plate, and a portion of the second surface; a second connector covers a portion of the first surface, the first side of the carrier plate, and a portion of the second surface; wherein the first end of the first connector and the first end of the second connector are located on the first surface of the carrier plate; the second end of the first connector and the second end of the second connector are located on the second surface of the carrier plate.

[0014] In this embodiment, one end of the connector is located on the first surface for connecting the coil, and the other end is located on the second surface for connecting the circuit board. Thus, the coil assembly can be easily assembled onto the circuit board by means of soldering or other methods, thereby improving the assembly efficiency of the switching power supply.

[0015] In one possible implementation, the carrier includes a first side and a second side disposed opposite to each other; wherein the first side of the carrier plate is close to the lead end of the coil, and the second side of the carrier plate is far from the lead end of the coil; a first connector covers the first side and a portion of the second surface of the carrier plate; a second connector covers the first side and a portion of the second surface of the carrier plate; wherein the first end of the first connector and the first end of the second connector are at least partially located on the first side of the carrier plate; the second end of the first connector and the second end of the second connector are located on the second surface of the carrier plate.

[0016] In this embodiment, one end of the connector is located on the first surface for connecting the coil, and the other end is located on the second surface for connecting the circuit board. This allows the circuit board and the coil to be easily connected together, improving the manufacturing efficiency of the switching power supply.

[0017] In one possible implementation, the coil assembly further includes a first adhesive element for bonding the coil to a first surface of the carrier plate.

[0018] In this embodiment, the coil is fixed to the bearing plate by adhesive bonding, thereby improving the stability of the transformer operation.

[0019] In one possible implementation, the coil assembly further includes a second adhesive for securing the coil lead to a first surface of the carrier plate.

[0020] In this embodiment, the coil leads are fixed to the bearing plate by bonding, thus avoiding the impact of unstable coil lead positions on the transformer's operating performance.

[0021] In one possible implementation, the carrier plate further includes a groove in which the coil is disposed.

[0022] In this embodiment, fixing the coil into the groove of the carrier plate improves the efficiency of coil assembly and ensures the stability of the coil's position on the carrier plate.

[0023] In one possible implementation, the first surface of the carrier plate is provided with an adsorption area located between the two leads of the coil; the adsorption area is used for the assembly equipment to adsorb the carrier plate.

[0024] In this embodiment, the support plate can be operated by adsorption, which allows for convenient suction and removal of the support plate, thus improving the efficiency of automated preparation.

[0025] In one possible implementation, the circuit board further includes a third through hole and a fourth through hole, which are located on both sides of the first through hole and arranged in a row; the magnetic core also includes two side posts, one of which passes through the third through hole and the other passes through the fourth through hole.

[0026] In one possible implementation, the transformer is a step-down transformer, with the coil used as the primary winding and the PCB winding used as the secondary winding; wherein the number of turns of the coil is greater than the number of turns of the PCB winding.

[0027] By using a coil as the primary side of the transformer and using Litz wire to reduce the AC resistance of the coil, the power loss on the primary side is reduced, thereby reducing the overall power loss of the switching power supply.

[0028] In a second aspect, a computing device is provided, comprising a switching power supply and a load as described in the first aspect and its various possible embodiments, wherein the switching power supply and the load are electrically connected, and the switching power supply is used to supply power to the load. Attached Figure Description

[0029] Figure 1 This is a top view of a switching power supply provided in an embodiment of this application;

[0030] Figure 2 yes Figure 1 The side view of the switching power supply shown;

[0031] Figure 3 This is a top view of a carrier plate equipped with a coil, provided in an embodiment of this application;

[0032] Figure 4A yes Figure 3 Side view of the support plate shown;

[0033] Figure 4B This is a side view of a carrier plate equipped with a coil, provided in an embodiment of this application;

[0034] Figure 4C This is a side view of a carrier plate equipped with a coil, provided in an embodiment of this application;

[0035] Figure 4D This is a side view of a carrier plate equipped with a coil, provided in an embodiment of this application;

[0036] Figure 5 This is a flowchart illustrating the fabrication process of a transformer used in a switching power supply, as provided in an embodiment of this application. Detailed Implementation

[0037] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them.

[0038] In the description of the embodiments of this application, "one embodiment" or "some embodiments" means that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of the embodiments of this application, do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized.

[0039] In the description of the embodiments of this application, unless otherwise stated, " / " means "or", for example, A / B can mean A or B; "and / or" in this document is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Furthermore, in the description of the embodiments of this application, "multiple" refers to two or more.

[0040] In the description of the embodiments of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. The terms "comprising," "including," "having," and variations thereof all mean "including but not limited to," unless otherwise specifically emphasized.

[0041] Servers, switches, computers, and other computing devices all include switching power supplies. These power supplies provide power to the load components, including fans, motherboards, network cards, etc. A switching power supply converts the input AC voltage into the DC voltage required by the downstream load and then outputs the supply voltage to the load, ensuring its normal operation.

[0042] High power density switching power supplies are a key pursuit in the development of power electronics technology, while high power efficiency is required for energy conservation, environmental protection, and cost savings. Therefore, it is necessary to continuously improve the power density and efficiency of switching power supplies. Power density refers to the ratio of the output power of a switching power supply to its volume. Power efficiency, also known as conversion efficiency, refers to the ratio of the output power of a switching power supply to the power consumed by the switching power supply.

[0043] In one feasible approach, the switching power supply may include a DC-DC converter, which can employ a planar transformer for voltage conversion. Both the primary and secondary windings of the planar transformer utilize printed circuit board (PCB) windings. This solution offers high power density and allows for automated manufacturing, resulting in high production efficiency. However, the planar transformer has a high alternating current resistance (ACR), leading to significant transformer losses at high frequencies and consequently, lower power supply efficiency.

[0044] In another feasible approach, the DC-DC converter can employ a wound transformer for voltage conversion. Both the primary and secondary sides of the wound transformer utilize coils made of multiple thin wires wound in parallel. While this approach offers a lower efficiency coefficient (ACR) and higher power efficiency, it suffers from lower space utilization, resulting in lower power density. Furthermore, this approach requires manual fabrication, leading to low automation and low fabrication efficiency.

[0045] Please see Figure 1 and Figure 2 This application provides a switching power supply 100, which includes a circuit board 110, a coil assembly, and a magnetic core 130. In the switching power supply 100, the circuit board 110 has a through-hole B1 and a PCB winding disposed around the through-hole B1. The PCB winding is disposed within the circuit board 110.

[0046] A coil assembly is mounted on top of the circuit board 110. This coil assembly includes a coil 120, a carrier plate 124, and two connectors 1241. These connectors can also be referred to as pins. For ease of description, one of the two connectors 1241 can be referred to as connector 1241a, and the other as 1241b. Furthermore, in the following description, unless otherwise specified, connectors 1241a and 1241b can be collectively referred to as connector 1241.

[0047] The carrier plate 124 has surfaces C1 and C2 arranged opposite to each other, with surface C2 facing the circuit board 110. The coil 120 is disposed and fixed on surface C1 of the carrier plate. The D1 end of connector 1241a is connected to one end of the coil 120, and the D2 end is electrically connected to the circuit board 110. The D1 end of connector 1241b is connected to the other end of the coil 120, and the D2 end is electrically connected to the circuit board 110.

[0048] The carrier plate 134 has a through hole B2 opposite to the through hole B1, and the coil 120 surrounds the through hole B2. The magnetic core 130 includes a center post that passes through the through hole B2, thereby enabling the magnetic core 130, the coil 120, and the PCB winding to form a transformer. Specifically, one of the coil 120 and the PCB winding can serve as the primary side of the transformer, and the other can serve as the secondary side. For example, in a step-down transformer, the coil 120 serves as the primary winding, and the PCB winding serves as the secondary winding.

[0049] Next, the solutions provided in the embodiments of this application will be described in detail.

[0050] Please continue reading. Figure 1 and Figure 2 The switching power supply 100 includes a circuit board 110. A circuit board, also known as a printed circuit board, is used to carry electronic devices and provide electrical connection lines for the electronic devices.

[0051] The circuit board 110 may include a PCB winding. A PCB winding refers to a coil fabricated on one or more wiring layers within the circuit board. For example, when the wiring layer is a copper layer, a multi-turn coil can be fabricated on one or more copper layers to obtain a PCB winding with a set number of turns.

[0052] A through hole can be made on the circuit board 110 corresponding to the middle area of ​​the PCB winding, so that a through hole B1 is formed in the middle area of ​​the PCB winding. The through hole B1 allows the columnar magnetic core (such as the central column of the magnetic core 130) to pass through, so that the magnetic core can pass through the PCB winding and the PCB winding is sleeved on the magnetic core.

[0053] Continue reading Figure 1 and Figure 2 The switching power supply 100 also includes a coil 120 mounted on a circuit board 110. The coil 120 can be obtained by winding wires on a module and has a low ACR (Advanced Circuit Reduction). In some embodiments, the coil 120 can be wound with Litz wire. Litz wire refers to a plurality of insulated wires connected in parallel. The coil 120 wound with Litz wire has an even lower ACR.

[0054] The coil 120 is assembled onto the circuit board 110 after the circuit board 110 is manufactured. In other words, the circuit board 110 can be manufactured separately according to the circuit board manufacturing process, and the coil 120 can be manufactured separately according to the coil manufacturing process. Then, the two are assembled, which facilitates the automated assembly of the switching power supply 100 and improves manufacturing efficiency.

[0055] In some embodiments, the coil 120 can be fabricated as a surface mount device and mounted onto the circuit board 110 using surface mount technology (SMT). For example, the coil 120 can be used as a surface mount device, and a pick-and-place machine can be used to mount the coil 120 onto the circuit board 110, thereby achieving automated assembly of the coil 120 onto the circuit board 110.

[0056] In some embodiments, the coil 120 and the carrier plate 124 can form a coil assembly, which can be mounted on the circuit board 110 via the carrier plate 124 to achieve automated assembly. In the switching power supply 100, surface C2 of the carrier plate 124 contacts the circuit board 110, and surface C1 carries the coil 120. That is, the coil 120 can be mounted on surface C1 of the carrier plate 124, and surface C2 of the carrier plate 124 can be connected to the circuit board 110 to fix the carrier plate 124 and the coil 120 onto the circuit board 110.

[0057] Next, we will introduce each component of this coil assembly in detail.

[0058] The coil assembly includes a carrier plate 124 for mounting the coil 120. The carrier plate 124 has a through hole B2 at a position corresponding to the middle of the coil 120, the through hole B2 allowing a columnar magnetic core (e.g., the central column of the magnetic core 130) to pass through, thereby enabling the magnetic core to pass through the coil 120.

[0059] The carrier plate 124 is made of a rigid insulating material. The rigidity of the insulating material is such that, under the gravity of the coil 120, the carrier plate 124 will not deform or will undergo only slight deformation. Slight deformation refers to deformation that does not affect the automated equipment's assembly of the carrier plate 124 onto the circuit board 110. In one example, the insulating material can be any of a PCB board, a plastic board, or an epoxy resin board.

[0060] In one example, such as Figure 3 As shown, the carrier plate 124 has two connectors 1241 on the side away from the location of the coil 120. As described above, one of the two connectors 1241 can be referred to as connector 1241a, and the other as 1241b. Connector 1241a is electrically connected to one pin of the coil 120, and connector 1241b is electrically connected to the other pin of the coil 120. One pin of the coil 120 is one end of the coil 120, and the other pin is the other end of the coil 120. This forms a circuit with the coil 120. The preceding circuitry can provide voltage across the coil 120 via the two pins 1241 and the two pins of the coil 120, thereby generating current in the coil 120. The pins of the coil can also be referred to as the coil leads.

[0061] More specifically, such as Figure 4A As shown, connectors 1241 (i.e., connectors 1241a and 1241b) are U-shaped and cover the side of the carrier plate 124 away from the location of the coil 120, such that a portion of connector 1241 is on surface C1 of the carrier plate 124 and another portion is on surface C2 of the carrier plate 124. The portion of connector 1241 on surface C1 of the carrier plate 124 forms end D1 of connector 1241, used to connect to the lead of the coil 120. The portion of connector 1241 on the bottom surface of the carrier plate 124 forms end D2 of connector 1241, used to connect to the preamplifier circuit. More specifically, end D1 of connector 1241a connects to one lead of the coil 120, and end D1 of connector 1241b connects to the other lead of the coil 120. Both connectors 1241a and 1241b are connected to circuit board 110, and thus connected to the preamplifier circuit via circuit board 110.

[0062] In one example, the D1 terminal of connector 1241 serves as a solder pad for connecting the leads of coil 120 via soldering. For example, as shown... Figure 4A As shown, the lead of coil 120 can be soldered to end D1 of connector 1241 to form a welded seam 1221. Thus, the lead of coil 120 is connected to connector 1241.

[0063] In one example, the D2 terminal of connector 1241 serves as a solder pad for connecting to the preceding circuitry via soldering. For instance, a PCB trace (not shown) connected to the preceding circuitry is soldered to the D2 terminal of connector 1241. This connects connector 1241 to the preceding circuitry.

[0064] In another example, such as Figure 4B As shown, connectors 1241 (i.e., connectors 1241a and 1241b) are L-shaped. The L-shaped connectors 1241 are attached to the side of the carrier plate 124 furthest from the coil 120, such that a portion of the L-shape is below surface C2 of the carrier plate 124, and another portion is above surface C1; or, a portion of the L-shape is above surface C1 of the carrier plate 124, and another portion is below surface C2. The portion above or below the top surface serves as the D1 terminal of connector 1241, connecting to the lead of the coil 120, for example, by soldering. The portion below or below the bottom surface serves as the D2 terminal, forming a solder pad for connecting to the pre-amplifier circuitry. Thus, the pre-amplifier circuitry can be connected to the coil 120 via connectors 1241.

[0065] In yet another example, such as Figure 4CAs shown, connectors 1241 (i.e., connectors 1241a and 1241b) are cylindrical. Connector 1241 penetrates the support plate 124, with one end above the top surface of the support plate 124 and the other end below the bottom surface. The end of connector 1241 above the top surface of the support plate serves as terminal D1, connecting to one lead of coil 120, for example, by soldering. The end of connector 1241 below the top surface of the support plate serves as terminal D2, used to connect to the preceding circuitry.

[0066] In one example, such as Figure 3 and Figures 4A-4D As shown, the shape of the coil 120 can be fixed using shaping tape, and the shaped coil 120 can then be fixed to the carrier plate 124. In one example, the shaped coil 120 can be bonded to the carrier plate 124 using a first adhesive. The first adhesive can be dispensing glue. In one example, as... Figure 4D As shown, the carrier plate 124 has a groove that can hold the coil 120 in place. The coil 120 can be placed into the groove by an interference fit, and a pressing force is formed between the groove and the coil 120, thereby fixing the coil 120 to the carrier plate 124.

[0067] In some embodiments, such as Figure 3 As shown, the two connectors 1241 (i.e., connectors 1241a and 1241b) are positioned on the carrier plate 124 at a distance L1 from the position of the coil 120 on the carrier plate 124. The leads of the coil 120 are leads with a length not less than the distance L1. For example, the leads can be fixed to the carrier plate 124 by a second adhesive 123 to prevent movement. The second adhesive 123 can be a dispensing adhesive. There is a void area between connectors 1241a and 1241b, the coil 120, and the two leads (i.e., leads) of the coil 120. This void area can serve as an adsorption area 1242 for adsorbing the carrier plate 124 on which the coil 120 is mounted, thereby facilitating the mounting of the carrier plate 124 onto the circuit board 110. For example, the vacuum suction head of the automated processing equipment can act on the adsorption area 1242 to pick up the carrier plate 124, thereby moving the position of the carrier plate 124, for example, moving the carrier plate 124 onto the circuit board 110.

[0068] In some embodiments, the carrier plate 124 with coil 120 mounted can be used as a surface mount device and mounted onto the circuit board 110 via SMT. For example, the carrier plate 124 with coil 120 mounted can be used as a surface mount device, and the surface mount device (coil assembly) can be bonded and soldered onto the circuit board 110 using a pick-and-place machine.

[0069] Continue reading Figure 1 and Figure 2 The switching power supply 100 also includes a magnetic core 130. Magnetic core

[0070] The through hole in the middle region of coil 120 corresponds to the through hole in the middle region of PCB winding. The cylindrical magnetic core can pass through the through hole in the middle region of coil 120 and the through hole in the middle region of PCB winding. That is, the magnetic core 130 passes through the PCB winding and coil 120 of circuit board 110, so that the PCB winding and coil 120 are wound or sleeved on the cylindrical magnetic core.

[0071] In some embodiments, the magnetic core 130 may be composed of magnetic core 131 and magnetic core 132. Magnetic core 131 and magnetic core 132 are E-type magnetic cores, each including a central post and two side posts. The central post is located between the two side posts, and all three are connected by a core base. In the switching power supply 100, magnetic core 131 and magnetic core 132 are interlocked to form magnetic core 130. Magnetic core 132 may be located on the bottom surface of circuit board 110, extending from the bottom surface of circuit board 110 towards the circuit board 110. Magnetic core 132 may also be located on the top surface of circuit board 110. The central post of magnetic core 132 interlocks with and is bonded together with the central post of magnetic core 131. The central post of magnetic core 132 interlocks with and is bonded together with the side posts of magnetic core 131. The central post of magnetic core 132 or magnetic core 131 passes through coil 120 and PCB winding, so as to wind or sleeve coil 120 and PCB winding on magnetic core 130. In addition, the contact surface between magnetic core 132 and / or magnetic core 131 and circuit board 110 can be covered with adhesive, thereby bonding magnetic core 132 and / or magnetic core 131 to circuit board 110 together.

[0072] In one example of this embodiment, the circuit board 110 also has a through hole B3 located on one side of the through hole B1, and a through hole B4 located on the other side of the through hole B1. The through holes B3, B1, and B4 are arranged in a row and sequentially. The through holes B3, B1, and B4 respectively match the shapes of one side post, the middle post, and the other side post of the E-type magnetic core 131 (or magnetic core 132), so that one side post of the magnetic core 131 (or magnetic core 132) can pass through the through hole B3, the middle post can pass through the through hole B1, and the other side post can pass through the through hole B2, thereby realizing the interlocking of the magnetic core 131 and the magnetic core 132.

[0073] In one example of this example, when magnetic cores 131 and 132 are snapped together, the support plate 124 is positioned between the two side posts of magnetic core 131 or 132. That is, the two side posts of magnetic cores 131 and 132 are snapped together on the outside of the support plate 124.

[0074] In one example of this example, the carrier plate 124 also has a through hole B5 located on one side of through hole B12 and a through hole B6 located on the other side of through hole B2. Through holes B5, B2, and B6 are arranged in a row and sequentially. Through holes B5, B2, and B6 respectively match the shapes of one side post, the middle post, and the other side post of the type E magnetic core 131 (or magnetic core 132), so that one side post of magnetic core 131 (or magnetic core 132) can pass through through hole B5, the middle post can pass through through hole B2, and the other side post can pass through through hole B6, thereby realizing the interlocking of magnetic core 131 and magnetic core 132.

[0075] The preceding text only provided illustrative examples of how the magnetic core 130 is implemented and assembled into the switching power supply 100, and is not intended to limit its specific implementation. In other embodiments, the magnetic core 130 can also be of other forms, such as one of two mating magnetic cores being an E-type core and the other an I-type core. In this case, the central post of the E-type core can pass through the coil 120 and the PCB winding, so that the coil 120 and the PCB winding are wound or sleeved on the magnetic core 130.

[0076] Therefore, the magnetic core 130, coil 120, and PCB winding in circuit board 110 can form a transformer A1. Among them, coil 120 can serve as the primary side of transformer A1, and PCB winding in circuit board 110 can serve as the secondary side of transformer A1.

[0077] The primary side of a transformer is also called the primary winding, and the secondary side is also called the secondary winding. The primary winding can be connected to a power source, thereby generating current. Under the influence of the current in the primary winding, the magnetic core generates an alternating magnetic field. Under the influence of this alternating magnetic field, current is generated in the secondary winding. This achieves the transfer of energy from the primary winding to the secondary winding.

[0078] Compared to PCB windings, coil 120 has a lower AC resistance (ACR). Coil 120 is used as the primary winding of transformer A1 in switching power supply 100. Compared to transformers where both primary and secondary windings are PCB windings, transformer A1 has a lower AC resistance, resulting in lower power loss and higher power efficiency in switching power supply 100.

[0079] Furthermore, the PCB windings are fabricated directly on the circuit board, resulting in high space utilization. Using PCB windings as the secondary windings of transformer A1 in the switching power supply 100 helps to reduce the size of the switching power supply 100.

[0080] Furthermore, since the PCB winding is fabricated inside the circuit board, and the PCB winding and the traces on the circuit board are directly connected rather than being transferred through other lines, the DC resistance between the PCB winding and the traces on the circuit board is relatively small. Using the PCB winding as the secondary winding of the transformer A1 in the switching power supply 100 can also reduce the DC resistance between the transformer A1 and the traces on the circuit board 110, further reducing the power loss of the switching power supply 100.

[0081] In some embodiments, when transformer A1 is a step-down transformer, the number of turns in the primary winding is greater than the number of turns in the secondary winding. In this case, the number of turns in coil 120 is greater than the number of turns in the PCB winding. Coil 120 is used as the primary winding of transformer A1, and the PCB winding is used as the secondary winding of transformer A1. Since the more turns a winding has, the greater the loss caused by the winding's ACR (Adjustable Turn Rate). When the number of turns in the primary winding is less than that in the secondary winding, using coil 120, which has a smaller ACR, as the primary winding can significantly reduce the overall power loss of the switching power supply 100.

[0082] See Figure 5 This embodiment provides a manufacturing process for a transformer used in switching power supplies: the process may include the following steps.

[0083] Step 501: Prepare a circuit board 110 containing PCB windings.

[0084] Copper can be deposited on a circuit board in the form of coils, with the turns of the coils insulated from each other, to obtain a circuit board 110 containing PCB windings. In some embodiments, the circuit board may include multiple layers. Copper can be deposited on all or some layers of the multiple layers to obtain a PCB winding with a set number of turns.

[0085] A through hole B1 can be formed on the circuit board 110 corresponding to the middle area of ​​the PCB winding. The through hole B1 allows the cylindrical magnetic core to pass through, so that the magnetic core can pass through the PCB winding and the PCB winding can be fitted on the magnetic core.

[0086] Step 502: Assemble the coil 120 onto the circuit board 110.

[0087] According to design requirements, a wire (such as Litz wire) can be wound on the mold to obtain coil 120. After removing coil 120 from the mold, the shape of the coil can be fixed with shaping tape.

[0088] In some embodiments, the coil 120 can be mounted onto the circuit board 110 by adhesive soldering. In some embodiments, the coil 120 can be mounted onto the circuit board 110 as a surface mount device (SMT). For example, the coil can be mounted onto the circuit board 110 as a surface mount device using a pick-and-place machine. In some embodiments, the coil 120 can be fixed to a carrier plate 124, and then the coil 120 can be mounted onto the circuit board 110 by mounting the carrier plate 124 onto the circuit board 110. See the above description for details. Figure 3 and Figure 4D The embodiments shown will not be described in detail here. All of the aforementioned methods can achieve automated assembly of the coil to the circuit board.

[0089] In some embodiments, a pre-configured inverter circuit 140 and / or rectifier circuit 150 can be mounted onto the circuit board 110. Exemplarily, the inverter circuit 140 and / or rectifier circuit 150 can be mounted onto the circuit board 110 via surface mount technology (SMT). For example, a pick-and-place machine can be used to mount the inverter circuit 140 and / or rectifier circuit 150 onto the circuit board 110, thus achieving automated assembly of the inverter circuit and / or rectifier circuit onto the circuit board.

[0090] Step 503: Pass the magnetic core 130 through the coil 120 and the PCB winding, and assemble it on the circuit board 110.

[0091] In some embodiments, the magnetic core 130 may be composed of magnetic core 131 and magnetic core 132. Both magnetic core 131 and magnetic core 132 are E-shaped. Magnetic core 132 can be snapped onto the circuit board 110 from its bottom surface and from its top surface. The central post of magnetic core 132 and the central post of magnetic core 131 are interlocked and bonded together, for example, with adhesive. The central post of magnetic core 132 and the side posts of magnetic core 131 are interlocked and bonded together, for example, with adhesive. The central post of magnetic core 132 or magnetic core 131 passes through the coil 120 and the PCB winding, so that the coil 120 and the PCB winding are wound or sleeved on the magnetic core 130. Additionally, the contact surfaces of magnetic core 132 and / or magnetic core 131 with circuit board 110 can be covered with adhesive to bond magnetic core 132 and / or magnetic core 131 to circuit board 110.

[0092] In some embodiments, the magnetic core 130 may be I-shaped. The I-shaped magnetic core 130 may have a coil 120 and a PCB winding wound on it.

[0093] Therefore, a switching power supply 100 can be prepared.

[0094] Each step in the above-described preparation process can be automated, thereby improving the manufacturing efficiency of the switching power supply. Furthermore, the prepared switching power supply has a smaller volume, thus achieving higher power density. Additionally, the prepared switching power supply has low power loss and high power efficiency. Specifically, compared to existing automated planar transformer switching power supplies, the switching power supply prepared in this embodiment improves power efficiency, thereby achieving a higher energy efficiency level.

[0095] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A switching power supply, characterized in that, The switching power supply includes a circuit board and a transformer; wherein the transformer includes PCB windings, coil assemblies and magnetic cores; The PCB windings are disposed within the circuit board; The coil assembly is disposed on the circuit board; wherein the AC resistance ACR of the coil in the coil assembly is less than the ACR of the PCB winding; The magnetic core is mounted on the circuit board and extends through the PCB winding and the coil; The PCB winding serves as one of the primary and secondary sides of the transformer; the coil serves as the other of the primary and secondary sides of the transformer.

2. The switching power supply according to claim 1, characterized in that, The coil is made of wire.

3. The switching power supply according to claim 1 or 2, characterized in that, The coil assembly also includes a carrier plate, a first connector, and a second connector; The carrier plate has a through hole that allows the magnetic core to pass through, and the coil is fixed to a first surface of the carrier plate around the through hole; the second surface of the carrier plate opposite to the first surface faces the circuit board. The first connector and the second connector are at least partially disposed on the second surface of the carrier plate; the first connector and the second connector each include a first end and a second end; wherein, the first end of the first connector is electrically connected to one end of the coil and the second end is electrically connected to the circuit board; the first end of the second connector is electrically connected to the other end of the coil and the second end is electrically connected to the circuit board.

4. The switching power supply according to claim 3, characterized in that, The support plate includes two connecting through holes; the first connector passes through the support plate through one of the connecting through holes; the second connector passes through the support plate through the other connecting through hole. Wherein, the first end of the first connector and the first end of the second connector protrude from the first surface of the support plate; the second end of the first connector and the second end of the second connector protrude from the second surface of the support plate.

5. The switching power supply according to claim 3, characterized in that, The support plate includes a first side and a second side disposed opposite to each other; the first side and the second side are located between the first surface and the second surface; wherein, the first side of the support plate is close to the lead-out end of the coil, and the second side of the support plate is far away from the lead-out end of the coil; The first connector covers a portion of the first surface, the first side surface of the support plate, and a portion of the second surface; the second connector covers a portion of the first surface, the first side surface of the support plate, and a portion of the second surface. Wherein, the first end of the first connector and the first end of the second connector are located on the first surface of the support plate; the second end of the first connector and the second end of the second connector are located on the second surface of the support plate.

6. The switching power supply according to claim 3, characterized in that, The support plate includes a first side and a second side disposed opposite to each other; wherein, the first side of the support plate is close to the output end of the coil, and the second side of the support plate is far away from the output end of the coil; The first connector covers the first side surface and part of the second surface of the support plate; The second connector covers the first side surface and part of the second surface of the support plate; Wherein, the first end of the first connector and the first end of the second connector are at least partially located on the first side of the support plate; the second end of the first connector and the second end of the second connector are located on the second surface of the support plate.

7. The switching power supply according to any one of claims 3-6, characterized in that, The coil assembly further includes a first adhesive member for bonding the coil to a first surface of the carrier plate.

8. The switching power supply according to any one of claims 3-6, characterized in that, The coil assembly further includes a second adhesive component for fixing the coil lead to a first surface of the carrier plate.

9. The switching power supply according to claim 1, characterized in that, The transformer is a step-down transformer, and the coil is used as the primary coil of the transformer; the PCB winding is used as the secondary coil of the transformer; wherein, the number of turns of the coil is greater than the number of turns of the coil in the PCB winding.

10. A computing device, characterized in that: The computing device includes a switching power supply and a load as described in any one of claims 1-9, the switching power supply and the load being electrically connected, the switching power supply being used to supply power to the load.

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