Transformer

Abstract

The invention relates to a transformer. A first insulating layer of the transformer is interposed between a plurality of coils on a secondary side. The transformer according to the present invention comprises: a core portion having an upper core and a lower core; a primary coil wound on the first bobbin and accommodated in the core portion; and a secondary coil inserted into the second bobbin and disposed at a side portion of the primary coil. The secondary coil includes a first insulating layer, a (2-1) th coil disposed on an upper portion of the first insulating layer, and a (2-2) th coil disposed on a lower portion of the first insulating layer. The first insulating portion and the second insulating portion are provided between the (2-1) th coil and the (2-2) th coil, and have different lamination numbers.

Description

Technical Field

[0001] The present disclosure relates to a transformer, and more particularly, to a transformer having a structure in which a first insulating layer is interposed between a plurality of secondary-side conductive plates, and a method of manufacturing the same. Background Art

[0002] Generally, driving power is required to drive an electronic device, and a power supply device, such as a power supply unit (PSU), must be employed to supply the driving power to the electronic device.

[0003] In particular, display devices such as flat-panel televisions are being thinned and are being implemented in ever-increasing sizes. Therefore, there is a need to reduce the thickness of such large displays while meeting their increased power requirements.

[0004] In a power supply unit (PSU), a transformer occupies a relatively large volume compared to other components. In order to realize a slim transformer, a method of omitting a thicker component from the transformer or adjusting the number of thicker components is generally considered. For example, in recent years, a skeleton on which a primary coil and a secondary coil are wound to be fixed is omitted from a transformer constituting a power supply unit of a flat panel display device, or a plurality of low-capacity slim transformers are adopted.

[0005] In such PSUs, the increase in parasitic capacitance on the secondary side may cause a change in the output voltage under no-load conditions. Summary of the invention

[0006] Technical issues

[0007] The present disclosure is made to solve the above-mentioned problems in the related art, and an object of the present disclosure is to provide a transformer capable of maintaining secondary-side parasitic capacitance.

[0008] Another object of the present disclosure is to provide a transformer capable of preventing an increase in secondary-side parasitic capacitance in the transformer after molding.

[0009] Technical Solution

[0010] To achieve the above-mentioned purpose, a transformer according to an embodiment of the present disclosure may include: a core unit, the core unit including an upper core and a lower core; a primary coil, the primary coil wound on a first skeleton to be accommodated in the core unit; a secondary coil, the secondary coil inserted into a second skeleton to be arranged next to the primary coil; and a secondary coil, the secondary coil inserted into the second skeleton to be arranged next to the primary coil, wherein the secondary coil may include a first insulating layer, a 2-1 coil arranged on the first insulating layer, and a 2-2 coil arranged below the first insulating layer,

[0011] The secondary coil may include: a first insulating layer arranged between a plurality of coils, wherein a first insulating portion and a second insulating portion formed with different numbers of layers are arranged between a 2-1 coil and a 2-2 coil; a 2-1 coil, which is arranged on the first insulating layer; and a 2-2 coil, which is arranged under the first insulating layer, and a first insulating portion and a second insulating portion formed with different numbers of layers may be arranged between the 2-1 coil and the 2-2 coil.

[0012] In the transformer according to the present disclosure, the first insulating part may include a first insulating layer, a 2-1 insulating layer between a lower portion of the 2-1 coil and an upper portion of the first insulating layer, and a 2-2 insulating layer between an upper portion of the 2-2 coil and a lower portion of the first insulating layer.

[0013] In the transformer according to the present disclosure, the width of the first insulating layer may be smaller than the widths of the 2-1st coil and the 2-2nd coil.

[0014] In the transformer according to the present disclosure, the second insulating portion may be formed by extending the 2-1 insulating layer and the 2-2 insulating layer to opposite sides of the first insulating layer.

[0015] The transformer according to the present disclosure may include a third insulating portion formed by the second insulating portion extending between a middle portion of the second bobbin and the secondary coil.

[0016] The transformer according to the present disclosure may include a fourth insulating portion formed by extending the third insulating portion between a top portion of the second bobbin and the 2-2 coil and between a bottom portion of the second bobbin and the 2-1 coil.

[0017] In the transformer according to the present disclosure, the thickness of the second insulating portion may be greater than the entire thickness of the fourth insulating portion.

[0018] In the first insulating portion of the transformer according to the present disclosure, the thickness of the first insulating layer may be greater than the thicknesses of the 2-1st insulating layer and the 2-2nd insulating layer.

[0019] In the transformer according to the present disclosure, a width of the first insulating portion may be greater than a width of the second insulating portion.

[0020] In the first insulating portion of the transformer according to the present disclosure, the thickness of the first insulating layer may be greater than the thicknesses of the 2-1st insulating layer and the 2-2nd insulating layer.

[0021] Beneficial Effects

[0022] The transformer and the manufacturing method thereof according to the present disclosure can maintain a constant distance between a plurality of coils constituting a secondary coil, thereby preventing an increase in parasitic capacitance.

[0023] In addition, it is possible to prevent the output voltage of the transformer from changing due to an increase in secondary-side parasitic capacitance. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is an exploded perspective view showing an example of a configuration of a transformer according to an embodiment of the present disclosure.

[0025] Figure 2 is a plan view showing the shape of a secondary coil in which a first insulating layer is provided between two coils.

[0026] Figure 3 is a flow chart showing the progress of a method of manufacturing a transformer according to an embodiment of the present disclosure.

[0027] Figure 4 is a view showing the shape of a first bobbin included in the transformer according to the present disclosure.

[0028] Figure 5a to Figure 5d is a view showing the secondary coil assembling process.

[0029] Figure 6 : is a view showing a process of combining the upper core and the lower core in a molded state.

[0030] Figure 7a is a cross-sectional view showing an example of a fully assembled transformer cut along the y-direction.

[0031] Figure 7b It is shown in detail Figure 7a A cross-sectional view of the structure of the secondary coil. DETAILED DESCRIPTION

[0032] Various exemplary embodiments will now be described more fully with reference to the accompanying drawings, in which only some exemplary embodiments are shown. The specific structural and functional details disclosed herein are representative only for the purpose of describing the exemplary embodiments. However, the present disclosure may be embodied in many alternative forms and should not be construed as being limited to the exemplary embodiments set forth herein.

[0033] Therefore, although the exemplary embodiments of the present disclosure are capable of various modifications and alternative forms, their embodiments are shown by way of example in the drawings and will be described in detail herein. However, it should be understood that it is not intended to limit the present disclosure to the specific exemplary embodiments disclosed. On the contrary, the exemplary embodiments should cover all modifications, equivalents and alternatives within the scope of the present disclosure.

[0034] It should be understood that although the terms "first", "second", etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish elements from each other. For example, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element without departing from the scope of the exemplary embodiments of the present disclosure.

[0035] It should be understood that when an element is referred to as being "connected" or "coupled" to another element, it may be directly connected or coupled to the other element, or there may be intervening elements. Conversely, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements. Other words used to describe the relationship between elements (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.) should be interpreted in a similar manner.

[0036] The terms used herein are only used for the purpose of describing specific embodiments and are not intended to limit exemplary embodiments of the present disclosure. As used herein, singular forms are also intended to include plural forms, unless the context clearly indicates otherwise. It will be further understood that when used herein, the terms "including" or "having" specify the presence of the features, integers, steps, operations, elements, parts, or combinations thereof, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, or combinations thereof.

[0037] Unless otherwise defined, all terms (including technical or scientific terms) used herein have the same meaning as those generally understood by those skilled in the art. Unless explicitly defined in the specification, terms such as those defined in general dictionaries should be interpreted as having the same meaning as the terms in the context of the relevant technology, and should not be interpreted as having an ideal or overly formal meaning.

[0038] At the same time, when a certain embodiment can be implemented in different ways, the function or operation specified in a specific frame can be performed in an order different from the order shown in the flow chart. For example, two consecutive frames can be executed simultaneously, or in reverse order, depending on the related functions or operations.

[0039] Hereinafter, a transformer and a method of manufacturing the same according to the present disclosure will be described with reference to the accompanying drawings.

[0040] Figure 1 is an exploded perspective view showing an example of a configuration of a transformer according to an embodiment of the present disclosure. Figure 1 , the transformer according to the embodiment includes core units 110 and 120 and coil units 200 and 300 .

[0041] The core units 110 and 120 may have the characteristics of a magnetic circuit and thus may serve as a path for magnetic flux. The core units 110 and 120 may include an upper core 110 disposed at an upper position and a lower core 120 disposed at a lower position. The two cores 110 and 120 may be formed to be symmetrical or asymmetrical with each other in the vertical direction. However, for ease of explanation, the following description is given under the assumption that the two cores are formed to be symmetrical with each other up and down.

[0042] Each of the upper core 110 and the lower core 120 may include a main body having a flat plate shape and a plurality of legs OL1-1, OL1-2, OL2-1, OL2-2, CL1, and CL2, which protrude from the main body in a thickness direction (i.e., a Z-axis direction) and extend in a predetermined direction. For example, the plurality of legs of the upper core 110 may include two outer legs OL1-1 and OL1-2 and a central leg CL1, which extend in one axis (e.g., an X-axis) direction and are spaced apart from each other in another axis (e.g., a Y-axis) direction when viewed in a plan view, and the central leg CL1 is disposed between the two outer legs OL1-1 and OL1-2.

[0043] When the upper core 110 and the lower core 120 are coupled to each other in the vertical direction, each of the outer legs OL1-1 and OL1-2 and the center leg CL1 of the upper core 110 faces a corresponding one of the outer legs OL2-1 and OL2-2 and the center leg CL2 of the lower core 120. In this case, a gap having a predetermined distance (e.g., 10 to 100 μm, but not necessarily limited thereto) may be formed between at least one pair of the pairs of outer legs OL1-1, OL1-2, OL2-1, and OL2-2 facing each other and the pairs of center legs CL1 and CL2 facing each other. In addition, the core units 110 and 120 may include a magnetic material, such as iron or ferrite, but the present disclosure is not necessarily limited thereto.

[0044] The coil units 200 and 300 may include a primary coil 200 and a secondary coil 300 .

[0045] The primary coil 200 may be wound around the central legs CL1 and CL2, and may be a multi-winding coil in which a rigid metal conductor (e.g., a copper wire) is wound multiple times in a spiral or flat spiral shape, but the present disclosure is not necessarily limited thereto. For example, the primary coil 200 may be made of fiber yarn-wound enameled wire (USTC wire), stranded wire, triple-insulated wire (TIW), etc.

[0046] The secondary coil 300 may include a 2-1st coil 310 having a planar shape, a 2-2nd coil 320 , and a first insulating layer 330 disposed between the two coils 310 and 320 .

[0047] The 2-1st coil 310 and the 2-2nd coil 320 may include a conductive metal (eg, copper or aluminum), and may have a planar shape that is bilaterally symmetrical to each other, but the present disclosure is not necessarily limited thereto.

[0048] The 2-1st coil 310 and the 2-2nd coil 320 may be aligned and stacked around the central legs CL1 and CL2 of the core units 110 and 120 , and each coil may form one turn.

[0049] The end portions 311 , 312 , 321 , and 322 of the coils 310 and 320 may be led out in the same direction, and the leading direction may be opposite to the leading direction of both end portions 210 , 220 of the wire constituting the primary coil 200 , but the present disclosure is not necessarily limited thereto.

[0050] Central end portions of the 2-1st coil 310 and the 2-2nd coil 320 have a short-circuit pattern in a center-tap structure.

[0051] like Figure 2 As shown, the first insulating layer 330 may have a "U" shape according to the shapes of the two coils 310 and 320, and the width W2 of the first insulating layer 330 may be equal to or less than the width W1 of the two coils 310 and 320. The length L1 of one side of the first insulating layer 330 is formed to be less than the length of the straight portion of each of the two coils 310 and 320. The first insulating layer 330 may include one of ketone, polyimide-based material, polyethylene terephthalate (PET), silicone, and epoxy-based material.

[0052] Figure 3 is a flow chart showing a process of manufacturing a transformer according to an embodiment of the present disclosure. The process of manufacturing a transformer according to the present disclosure generally includes a primary coil forming process S100, a secondary coil forming process S200, and an upper core / lower core combining process S300.

[0053] The primary coil forming process S100 includes a step of winding a primary coil on a first bobbin (S101) and a step of performing primary molding after the winding is completed (S102).

[0054] The secondary coil molding process S200 includes the step of placing the 2-1 coil on the second skeleton (S201), the step of placing the first insulating layer on the 2-1 coil (S202), the step of placing the 2-2 coil on the first insulating layer (S203), and the step of performing secondary molding after completing the placement of the secondary coil (S204).

[0055] Hereinafter, the transformer assembly process according to the present disclosure will be described in more detail.

[0056] First, if Figure 4 As shown, prepare (prepare, prepare) the first skeleton. The first skeleton 510 may include a first top portion 511, a first middle portion 513 and a first bottom portion 512. Each of the first top portion 511 and the first bottom portion 512 may have a rectangular planar shape with rounded corners, but the present disclosure is not necessarily limited to this. In addition, the first bottom portion 512 may have a planar shape that extends further outward than the first top portion 511 in the spacing direction of the legs (i.e., the X-axis direction).

[0057] The first middle portion 513 may be disposed between the first top portion 511 and the first bottom portion 512 in the vertical direction, and may insulate a wire (not shown) constituting the primary coil from the central leg. A space defined by a lower surface of the first top portion 511, an outer side surface of the first middle portion 513, and a portion of an upper surface of the first bottom portion 512 may be used as an accommodation space for accommodating the wire constituting the primary coil.

[0058] After the primary coil is wound on the first bobbin 510, primary injection molding is performed to firmly fix the primary coil. Although the first bobbin 510 is filled with injection molding liquid, a distance from the secondary coil is maintained so that a parasitic capacitance value can be maintained.

[0059] After the primary coil is formed, a second frame 520 to be placed outside the primary coil is prepared, as shown in Figure 5. The second frame 520 may include a second top portion 521 and a second bottom portion 522. Although not shown, a second middle portion may be disposed between the second top portion 521 and the second bottom portion 522 in a vertical direction to insulate the primary coil from the secondary coil.

[0060] like Figure 5b As shown, the 2-1st coil 310 is inserted and placed between the second bottom portion 522 and the second top portion 521 of the second bobbin 520. In this case, the terminating end portions 311 and 312 of the 2-1st coil 310 are disposed in a direction opposite to the terminal portion TM1 of the primary coil.

[0061] Then, if Figure 5c As shown, the first insulating layer 330 is placed on the 2-1 coil 310. Then, as Figure 5d As shown, the 2-2nd coil 320 is placed on the first insulating layer 330 such that the terminating end portions 321 and 322 thereof are arranged in a direction opposite to the terminal portion TM1 of the primary coil, and then secondary molding is performed.

[0062] After performing the secondary molding, such as Figure 6As shown, the upper core 110 and the lower core 120 are placed above and below the frame and combined with the frame.

[0063] Figure 7a is a cross-sectional view showing an example of a fully assembled transformer cut along the y direction, and Figure 7b It is shown in detail Figure 7a A cross-sectional view of the structure of the secondary coil.

[0064] The first bobbin 510 and the second bobbin 520 are disposed between the core units 110 and 120 and the coil units 200 and 300 .

[0065] A symmetrical structure is shown with respect to the center legs CL1 and CL2 facing each other of the upper core 110 and the lower core 120. The primary coil 200 and the secondary coil 300 may be located between the center legs CL1 and CL2 and the outer legs OL1-1 and OL2-1 on one side, and between the center legs CL1 and CL2 and the outer legs OL1-2 and OL2-2 on the opposite side.

[0066] The primary coil 200 is wound on the first bobbin 510, and the first insulating layer 330 is disposed between the 2-1 coil 310 and the 2-2 coil 320 constituting the secondary coil 300. The molded portion 340 is formed as an insulating filler in a portion of the space of the second bobbin 520 where the secondary coil 300 is not disposed.

[0067] A total of four insulating parts are included between the secondary coil 300 and the second skeleton 520 of the transformer according to the present disclosure. The first insulating part a is formed as a multilayer, while the second insulating part b is formed as a single layer. That is, the number of layers of the insulating parts is different. The first insulating part a includes a first insulating layer 330 disposed between the 2-1 coil 310 and the 2-2 coil 320, a 2-1 insulating layer 341 located between the 2-1 coil 310 and the first insulating layer 330, and a 2-2 insulating layer 342 located between the 2-2 coil 320 and the first insulating layer 330. The second insulating part b is formed by extending the 2-1 insulating layer 341 and the 2-2 insulating layer 342 to the opposite side of the first insulating layer 330 to form a single layer.

[0068] The width of the first insulating portion a is greater than the width of the second insulating portion b.

[0069] The third insulating portion c is formed by the second insulating portion b extending between the middle portion 520 -M of the second bobbin 520 and the secondary coil 300 .

[0070] The fourth insulating part d includes the following insulating areas: an insulating area formed by extending the third insulating part c between the top part 520-T of the second skeleton and the 2-2 coil 320, and an insulating area formed by extending the third insulating part c between the bottom part 520-B of the second skeleton and the 2-1 coil 310.

[0071] The width W1 of the first insulating layer 330 is smaller than the width W2 of the 2-1 coil 310 and the 2-2 coil 320 .

[0072] In the first insulating portion a, a thickness H1 of the first insulating layer 330 is greater than a sum of a thickness H21 of the 2-1st insulating layer 341 and a thickness H22 of the 2-2nd insulating layer 342 .

[0073] The thickness of the second insulating portion b is greater than the sum of the thicknesses of the two insulating regions of the fourth insulating portion d.

[0074] In this way, the 2-1 coil 310 and the 2-2 coil 32 are forcibly separated by the first insulating layer 330 and then injection molding is performed, thereby minimizing the increase of parasitic capacitance, thereby reducing the occurrence of output voltage failure under the TV power no-load operation condition.

[0075] Although exemplary embodiments of the present disclosure have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the present disclosure as disclosed in the accompanying claims.

[0076] Industrial Applicability

[0077] The transformer according to the present disclosure may be used as a power supply unit in a flat panel display device.

Claims

1. A transformer, comprising: a core unit, the core unit comprising an upper core and a lower core; a primary coil wound on a first bobbin and accommodated in the core unit; a secondary coil inserted into the second bobbin and disposed on a side portion of the primary coil, Wherein, the secondary coil comprises: a first insulating layer; a 2-1st coil, the 2-1st coil being disposed on an upper portion of the first insulating layer; and The 2-2 coil is disposed at the lower part of the first insulating layer, and The first insulating portion and the second insulating portion formed with different numbers of layers are arranged between the 2-1 coil and the 2-2 coil.

2. The transformer according to claim 1, wherein: The first insulating portion comprises: the first insulating layer; a 2-1 insulating layer, the 2-1 insulating layer being between a lower portion of the 2-1 coil and an upper portion of the first insulating layer; and A 2-2 insulating layer is provided between an upper portion of the 2-2 coil and a lower portion of the first insulating layer.

3. The transformer according to claim 1, wherein: The first insulating layer has a width smaller than widths of the 2-1 coil and the 2-2 coil.

4. The transformer according to claim 2, wherein: The second insulating portion is formed by extending the 2-1 insulating layer and the 2-2 insulating layer to both sides of the first insulating layer. 5 . The transformer according to claim 4 , comprising a third insulating portion formed by extending the second insulating portion between a middle portion of the second bobbin and the secondary coil.

6. The transformer according to claim 5, comprising a fourth insulating portion formed by extending the third insulating portion between a top portion of the second bobbin and the 2-2 coil and between a bottom portion of the second bobbin and the 2-1 coil.

7. The transformer according to claim 6, wherein: The thickness of the second insulating portion is greater than the sum of the thicknesses of the fourth insulating portions.

8. The transformer according to claim 2, wherein: In the first insulating portion, a thickness of the first insulating layer is greater than thicknesses of the 2-1 insulating layer and the 2-2 insulating layer.

9. The transformer according to claim 1, wherein: A width of the first insulating portion is greater than a width of the second insulating portion.

10. The transformer according to claim 2, wherein: In the first insulating portion, a thickness of the first insulating layer is greater than a sum of a thickness of the 2-1 insulating layer and a thickness of the 2-2 insulating layer.

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