Bobbin and magnetic member

Abstract

The invention relates to a bobbin for supporting an insulated winding, comprising a base body having an outer surface around which the winding is wound to define a winding axis; wherein the outer surface comprises at least one threaded portion spiraling along a longitudinal axis of the base body, the threaded portion defining a threaded protrusion and a threaded base; the winding includes a plurality of radial winding layers stacked in a radial direction perpendicular to the winding axis, and at least one radial winding layer is inserted into the at least one threaded portion. The invention also relates to a magnetic component comprising a spool. The bobbin provided by the invention has a compact size, can be efficiently cooled, and allows simple and efficient manufacturing.

Description

Technical Field

[0001] The invention relates to a bobbin for supporting an insulated winding and also to a magnetic component comprising at least one such bobbin. Background Art

[0002] Generally, bobbins for supporting electrical windings, for example in transformers, are known.

[0003] For example, JP H07-130562 A discloses a bobbin structure for a flyback transformer. A low-voltage bobbin includes spiral grooves for providing a winding therein. The winding itself is litz wire and is uninsulated. Therefore, its spiral grooves provide insulation between two adjacent winding layers along the winding axis. Furthermore, this known flyback transformer includes a low-voltage bobbin and a high-voltage bobbin. The input primary winding is wound on the low-voltage bobbin, and the high-voltage secondary output winding is wound on a high-voltage bobbin outside the low-voltage bobbin. In other words, the flyback transformer includes a low-voltage bobbin for the primary winding and a high-voltage bobbin for the secondary winding. These bobbins are separated and insulated from each other by epoxy resin.

[0004] The flyback transformer of JP H07-130562 A has several disadvantages. One is that the bobbin configuration requires multiple bobbins to form the transformer's primary and secondary windings. Furthermore, due to the lack of wire insulation and the configuration of the spiral grooves, the litz wire cannot be stacked radially. Specifically, it is impossible for any part of the winding to come into contact with another part of the same winding without short-circuiting the winding and affecting the number of turns and electrical diameter of the winding. Therefore, it is impossible to radially stack different winding sections, such as the primary and secondary windings. Furthermore, particularly because multiple bobbins are required to provide the primary and secondary windings, the flyback transformer of JP H07-130562 A is very space-consuming and its cooling performance is inefficient.

[0005] JP 7168902 B2 discloses a bobbin and coil arrangement. The bobbin includes multiple winding separator flanges that separate adjacent winding sections along the winding axis of each winding section. The winding separator flanges are formed on the outer periphery of the bobbin. Adjacent winding sections formed in each winding separator flange are connected by a connecting groove. This bobbin and coil arrangement has disadvantages in terms of ease and efficiency of manufacturing, particularly when considering automated winding processes, and also fails to provide for adequate stacking of multiple radial winding layers.

[0006] A rotary transformer winding tool is known from CN 217484289 U. In this tool, a coil is wound around a rotary transformer. However, this rotary transformer winding tool also has the above-mentioned disadvantages, in particular, difficulty in manufacturing and winding, low cooling efficiency, and large space requirements. Summary of the Invention

[0007] The present invention aims to overcome these drawbacks. In particular, it is an object of the present invention to provide a bobbin for supporting an insulated winding having compact dimensions, which can be efficiently cooled and which allows for easy and efficient manufacturing, particularly for the winding process. Furthermore, it is an object of the present invention to provide a magnetic component having these advantages.

[0008] In particular, these objectives are achieved by a bobbin according to the present invention. The bobbin is configured to support an insulated winding. The bobbin comprises a base having an outer surface around which the winding is wound to define a winding axis. The outer surface comprises at least one threaded portion spiraling along a longitudinal axis of the base, the threaded portion defining one or more thread projections and one or more thread roots. The winding of the bobbin comprises a plurality of radial winding layers stacked in a radial direction perpendicular to the winding axis. Furthermore, at least one radial winding layer is inserted into at least one threaded portion.

[0009] The at least one threaded portion of the bobbin facilitates its manufacture, particularly for winding processes using automated winding equipment. Furthermore, by providing multiple radial winding layers, more portions of the winding can be cooled collectively, thereby improving its cooling efficiency. Furthermore, since the winding is insulated, the radial winding layers can have different electrical potentials and, for example, serve as part of both the primary and secondary windings (for different radial winding layers).

[0010] In the above and below, the following directions and axes are defined. In the finished or manufactured state, the winding surrounds the outer surface of the base of the bobbin, thereby defining a winding axis, which is the axis around which the winding is wound. In particular, the winding axis extends along the longitudinal axis of the base. In some embodiments, the winding axis and the longitudinal axis of the base are parallel to each other. In addition, the radial direction is perpendicular to the winding axis. In the above and below, the radial direction extends from the winding axis to the outer surface of the base. In other words, a positive radial direction is defined as extending from the winding axis to the outer surface, while a negative radial direction is defined as extending from the outer surface to the winding axis.

[0011] Furthermore, in the text above and below, the terms "thread projection" and "thread base" are used. A thread projection in this context refers to a projection of a thread (e.g., a screw thread) that defines the pitch of the thread. Furthermore, the thread base refers to the portion of the thread between adjacent projections. Furthermore, in the text above and below, a threaded portion is described as spiraling along the longitudinal axis of the base. This term refers to a helical shape whose spiral axis is along or parallel to the longitudinal axis of the base. Furthermore, the term "following the spiral extension" or similar terms refers to, in particular, a threaded portion as viewed along the longitudinal axis and in the circumferential direction of the base.

[0012] In this respect, although a single threaded portion may be primarily defined as comprising or consisting of one thread projection and one thread base (the thread base being defined by the pitch of the thread projection) that are spiraled together in a helical shape, in the above and below, a plurality of thread projections and thread bases are referred to as adjacent elements in a threaded portion when following the longitudinal axis of the base.

[0013] In some embodiments, the thread base corresponds to the portion of the base body's outer surface between the thread protrusions. Specifically, the thread base is flush with (the rest of) the outer surface. In other alternative embodiments, the thread base is not flush with the outer surface. For example, the portion of the base body corresponding to the thread base is thicker or wider than portions of the base body other than the at least one threaded portion. In other words, at least one threaded portion is radially elevated relative to the non-threaded portions of the base body. In some embodiments, each threaded portion is elevated by the same amount, or one or more (and in particular each) threaded portion is elevated by a different amount. Thus, different portions of a spool (e.g., corresponding to different winding types or applications) can have different (radial and / or longitudinal) dimensions, providing greater flexibility in use and improved cooling efficiency.

[0014] In some embodiments, one longitudinal winding layer is inserted between two thread protrusions of the threaded portion. In other words, the threaded portion separates two adjacent longitudinal winding layers from each other along the longitudinal axis of the base body.

[0015] In some embodiments, the pitch of the threaded portion is equal to or greater than the cross-sectional diameter of the winding and less than twice the cross-sectional diameter of the winding. In some embodiments, the pitch of the threaded portion is such that at most one longitudinal winding layer can be inserted between two thread projections. In particular, at most one complete longitudinal winding layer can be inserted between two thread projections. In other words, for example, the pitch of the threaded portion can be equal to 1.5 times the cross-sectional diameter of the winding, so that a longitudinal winding layer can be inserted between two thread projections with a tolerance of half the cross-sectional diameter of the winding, without providing any further longitudinal winding layers between the two projections.

[0016] In some embodiments, the outer surface comprises a continuous thread portion. In this respect, a continuous thread portion is defined by a continuous thread base between continuous thread protrusions. On the other hand, in the above and below, discontinuous or interrupted thread protrusions are referred to as different thread portions.

[0017] In some embodiments, the thread base of the threaded portion is flat or concave. Therefore, the manufacturing simplicity and cooling efficiency of the bobbin are advantageously improved, while damage to the winding, especially damage to the winding insulation, is advantageously prevented.

[0018] In some embodiments, the base includes at least one flange at one end along its longitudinal axis. In further embodiments, the base includes a flange at each end along its longitudinal axis, i.e., two flanges. This advantageously prevents the winding from slipping off the spool, thereby improving manufacturing simplicity.

[0019] In some embodiments, the outer surface of the base includes at least one non-threaded portion at the end of the threaded portion along the longitudinal axis. Thus, for example, the spool can be provided with a transition portion that serves as the at least one non-threaded portion. This improves manufacturing simplicity and efficiency, particularly during the winding process. In particular, when the base includes at least one flange and at least one non-threaded portion located at the flange, the non-threaded portion advantageously prevents positioning errors when the winding is wound around the base.

[0020] In some embodiments, where the base includes at least one flange and at least one non-threaded portion located at an end (i.e., at the flange), at least two longitudinal winding layers are inserted into a corresponding non-threaded portion. The at least two longitudinal layers are in contact with each other. In some embodiments, more than two longitudinal layers are inserted into a corresponding non-threaded portion. For example, three or more, four or more, or five or more longitudinal layers are inserted into a corresponding non-threaded portion.

[0021] Furthermore, the spool includes multiple (e.g., two) such non-threaded portions, particularly at each end of the threaded portion along the longitudinal axis. In other words, the spool according to some embodiments includes two non-threaded portions and one threaded portion, with the threaded portion disposed between the non-threaded portions along the longitudinal axis. A flange is disposed at the end of each of the two non-threaded portions. This advantageously improves manufacturing simplicity and efficiency.

[0022] In a further embodiment, at least one radial winding layer is radially stacked on at least one thread projection of the threaded portion. Thus, an advantageously compact and space-saving positioning of the winding layers is achieved, thereby also improving their cooling efficiency.

[0023] In some embodiments, the pitch of the threaded portion is maintained constant along the longitudinal axis of the base. In other words, when following the helical shape of the base along its longitudinal axis, the distance between two adjacent thread protrusions is substantially constant. In this context, "fixed" means that the pitch is fixed within a manufacturing tolerance, for example, within ±10%. The constant pitch of the threaded portion has the advantage of simplifying the winding process, thereby improving manufacturing simplicity and efficiency.

[0024] In some embodiments, the cross-sectional shape of the thread projection, parallel to the longitudinal axis, remains constant along the helical extension of the threaded portion. In other words, the cross-sectional shape of the thread projection remains constant along the longitudinal axis and along the circumference of the base body (i.e., while following the helical extension of the threaded portion). This simplifies the manufacturing process for the spool, particularly the manufacturing process for the spool base body including the threaded portion.

[0025] In some embodiments, the cross-sectional shape of the thread projection, parallel to the longitudinal axis, varies along the helical extension of the threaded portion. In other words, the cross-sectional shape of the thread projection is not constant along the helical extension of the threaded portion. This advantageously enables a threaded portion geometry that increases manufacturing ease (particularly during the winding process) and / or reduces winding slip. Furthermore, the varying cross-sectional shape of the thread projection advantageously provides guidance on which parts of the base body are to receive more or less winding portions, thereby increasing manufacturing ease.

[0026] In some embodiments, the cross-sectional shape of the thread protrusion gradually decreases along the spiral extension of the threaded portion toward at least one end of the threaded protrusion. In other words, along the longitudinal axis, when following the spiral extension of the threaded portion, its cross-sectional shape gradually decreases toward at least one end of the threaded protrusion. In some embodiments, the cross-sectional shape of the threaded protrusion gradually decreases toward both ends of the threaded protrusion. Therefore, the reduced end of the threaded portion advantageously provides a transition between the non-threaded portion and the threaded portion of the base. Therefore, misalignment or positioning problems during the winding process are advantageously prevented or reduced. In addition, this reduced end of the threaded portion advantageously prevents damage to the winding by reducing the number of sharp edges of the threaded portion.

[0027] In some embodiments, a winding includes a first winding portion and a second winding portion that are electrically isolated from each other. In other words, the first winding portion and the second winding portion are not directly electrically connected to each other. Here, the definition of "electrically isolated from each other" means that the current induced by one (first) winding portion in the other (second) winding portion (e.g., in the example case of a transformer) falls within the definition of "electrically isolated from each other."

[0028] In some embodiments, in the above-described embodiments, only the radial winding layers of the first winding section of the winding are inserted into the threaded section. In other words, the windings of the second winding section or winding sections other than the first winding section are not inserted into the threaded section. In some embodiments, in embodiments where the bobbin includes multiple threaded sections, each such threaded section only has windings of one of the above-described winding sections inserted therein. For example, the first threaded section may only include windings of the first winding section, and the second threaded section may only include windings of the second winding section.

[0029] In some embodiments, only radial winding layers of a second winding portion of the winding are radially stacked over at least one thread protrusion of the threaded portion. For example, the windings of the first winding portion are inserted into the threaded portion. The windings of the second winding portion are then radially stacked over at least one thread protrusion of the threaded portion. In some embodiments, the windings of the second winding portion are not radially stacked over the windings of the first winding portion. In some embodiments, additional radial winding layers of the first winding portion are radially stacked over the windings of the first winding portion that are inserted into the threaded portion.

[0030] Furthermore, in some embodiments, the first winding portion and the second winding portion are at least partially arranged in a bifilar arrangement. Thus, ease and efficiency of manufacturing are advantageously achieved, especially with regard to the winding process.

[0031] In some embodiments, in a bifilar arrangement, in a first radial winding layer, the first winding portion is inserted into the threaded portion; in at least one further radial winding layer, the first winding portion and the second winding portion are arranged in a bifilar arrangement such that the second winding portion is radially stacked on the thread projections and such that the first winding portion is radially stacked on the first winding portion of the first radial winding layer. In some embodiments, the pitch of the threaded portion and the dimensions of the thread projections and the thread base correspond to the cross-sectional diameter of the windings of the first and second winding portions. The cross-sectional width of the thread projections, parallel to the longitudinal axis, is equal to the cross-sectional diameter of the windings of the first and / or second winding portions, in particular, equal to the cross-sectional diameter of all winding portions of the windings. Thus, ease and efficiency of manufacturing, as well as advantageous cooling efficiency, are achieved.

[0032] In some embodiments, the bobbin comprises a plurality of substrates. In some embodiments, the plurality of substrates are integrally formed with one another. Further, each of the plurality of substrates comprises a separate winding. In some embodiments, a winding wound around one substrate is connected in series with a winding wound around another substrate of the same bobbin, with only one or more winding portions being connected in series.

[0033] The present invention further relates to a magnetic component, comprising at least one bobbin according to any one of the above embodiments and examples.

[0034] In some embodiments, the magnetic component includes a transformer and / or a choke. In examples of magnetic components including a transformer, the first winding portion is part of the transformer's primary winding, and the second winding portion is part of the transformer's secondary winding. This provides a magnetic component, particularly a transformer, that has a compact, space-saving design and high cooling efficiency. The magnetic component can also be manufactured easily and efficiently, particularly with regard to the winding process.

[0035] In some embodiments, the magnetic component includes a plurality of bobbins, each bobbin forming part of a phase of a multi-phase transformer. For example, the magnetic component includes a three-phase transformer and corresponding three bobbins, each bobbin forming part of a phase of the transformer. Additional bobbins may form part of one or more chokes.

[0036] The above-described embodiments and configurations may be combined with each other. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The details, advantages and features of the embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0038] Figure 1 shows a schematic side view of a spool according to a first embodiment of the present invention;

[0039] Figure 2 shows a perspective view of a spool according to a first embodiment of the present invention;

[0040] Figure 3 shows a cross-sectional view of a spool according to a first embodiment of the present invention;

[0041] Figure 4 shows a schematic side view of a spool according to a second embodiment of the present invention;

[0042] Figure 5 shows a perspective view of a spool according to a second embodiment of the present invention;

[0043] Figure 6 shows a cross-sectional view of a spool according to a second embodiment of the present invention;

[0044] Figure 7 shows a schematic side view of a spool according to a third embodiment of the present invention;

[0045] Figure 8 shows a perspective view of a spool according to a third embodiment of the present invention;

[0046] Figure 9 shows a cross-sectional view of a spool according to a third embodiment of the present invention;

[0047] Figure 10A perspective view showing a spool according to a fourth embodiment of the present invention; and

[0048] Figure 11 A schematic diagram showing a magnetic component according to a fifth embodiment of the present invention is shown. DETAILED DESCRIPTION

[0049] The following will refer to Figures 1 to 3 The first embodiment of the present invention is described. Figure 1 shows a schematic side view of a spool 1 according to a first embodiment of the invention, Figure 2 shows a perspective view of a spool 1 according to a first embodiment of the invention, Figure 3 Shown is a cross-sectional view of a spool 1 according to a first embodiment of the invention.

[0050] In particular, for ease of explanation of the bobbin 1, Figure 1 and Figure 2 The insulating winding 2 of the bobbin 1 in this embodiment is omitted (specific reference will be made to Figure 3 In other words, Figure 1 and Figure 2 In particular, the bobbin 1 is shown before the winding 2 is wound, and Figure 3 The bobbin 1 is shown in the state after being wound on the winding 2. In addition, Figure 3 One radial half of the spool 1 is shown for ease of illustration.

[0051] The bobbin 1 comprises a base body 3 and an insulated winding 2. The base body 3 comprises an outer surface 4 around which the winding 2 is wound (see Figure 3 ).

[0052] In this embodiment, the outer surface 4 includes a threaded portion 6. Figure 1 and Figure 2 As shown, the threaded portion 6 is spiraled along the longitudinal axis 7 of the base body 3. The threaded portion 6 defines a thread projection 6.1 and a thread base 6.2.

[0053] The thread projections 6.1 project from the outer surface 4 in the radial direction 12. The thread base 6.2 corresponds to the outer surface 4 of the base body 3 between the thread projections 6.1. In other words, Figure 1 and Figure 2 As shown, the thread base 6 . 2 is flush with the outer surface 4 at the non-threaded portion 13 .

[0054] In this embodiment, the thread base 6.2 is flat. In an alternative embodiment, the thread base 6.2 is concave in the radial direction 12, thereby allowing the winding 2 to fit more tightly. The concave or flat configuration of the thread base 6.2 allows the winding 2 to fit tightly while preventing damage to the winding 2 during the winding process, such as damage to the insulation.

[0055] The pitch 8 of the threaded portion 6 in this embodiment is defined as the distance between two thread protrusions 6 . 1 along the longitudinal axis 7 , and the pitch 8 remains constant along the longitudinal axis 7 .

[0056] Furthermore, the cross-sectional shape of the thread projection 6.1 in this example, which is parallel to the longitudinal axis 7, remains constant along the spiral extension of the threaded portion 6. The cross-sectional shape plane here refers to a plane defined by the longitudinal axis 7 and the extension in the radial direction 12, for example. Figure 1 In FIG, the upper left end 23 of the threaded portion 6 shows the cross-sectional shape, which is rectangular here.

[0057] The base body 3 in this embodiment comprises two flanges 10 , each located at one end 11 of the base body along its longitudinal axis 7 .

[0058] like Figure 2 As shown, each of the two flanges 10 comprises a winding guide portion 24 for guiding the winding 2 from / to the bobbin 1 .

[0059] Now, refer to Figure 3 The insulated winding 2 of the bobbin 1 in this embodiment is described. In some embodiments, the insulated winding 2 is wound around the bobbin 1 using a winding process, such as automated winding. The winding 2 defines a winding axis 5 about which it is wound. In this embodiment, the winding axis 5 is parallel to the longitudinal axis 7. In particular, in this embodiment, the winding axis 5 is coaxial with the longitudinal axis 7.

[0060] The winding 2 comprises a plurality of (in this example exactly three) radial winding layers 2.1 - 2.3. The radial winding layers 2.1 - 2.3 are stacked in a radial direction 12. In this embodiment, the radial winding layers 2.1 - 2.3 are stacked perpendicular to the winding axis 5.

[0061] Furthermore, one radial winding layer 2.1 is inserted into the threaded portion 6. In particular, only one radial winding layer 2.1 is inserted into the threaded portion 6.

[0062] Furthermore, the winding 2 comprises a plurality (in this example exactly ten) of longitudinal layers 2 . 4 - 2 . 13 .

[0063] The pitch 8 of the threaded portion 6 is equal to or greater than the cross-sectional diameter 9 of the winding 2 (corresponding to the cross-sectional shape described above) and is less than twice the cross-sectional diameter 9 of the winding 2. In other words, only one longitudinal layer 2.4-2.13 is inserted between two thread projections 6.1 of the threaded portion 6. It should be noted that the pitch 8, by definition, includes both halves of the corresponding thread projection 6.1 (between which the pitch 8 is defined).

[0064] In an alternative definition to the above, the distance between two thread projections 6 . 1 , ie the width of the thread base 6 . 2 along the longitudinal axis 7 , is approximately equal to the cross-sectional diameter 9 of the winding 2 .

[0065] Furthermore, only one longitudinal layer 2.4 and only one radial winding layer 2.1 are inserted between two thread projections 6.1 of the threaded portion 6. In other words, the cross-sectional height 25 of the thread projection 6.1 in the radial direction 12 is approximately equal to the cross-sectional diameter 9 of the winding 2.

[0066] like Figure 1 and Figure 3 As shown and described above, base body 3 includes flange 10 and at least one non-threaded portion 13 located at end 11 (i.e., at flange 10). At least two longitudinal layers 2.12 and 2.13 of winding 2 are inserted into non-threaded portion 13 between flange 10 and first threaded projection 6.1 of threaded portion 6. These two longitudinal layers 2.12 and 2.13 are in contact with each other. This will now be described in more detail. A longitudinal layer 2.4 is provided at the other end 11, between flange 10 and the (last or fourth) threaded projection 6.1.

[0067] like Figure 3 As indicated by different shading in FIG. 1 , in this embodiment, the winding 2 includes a first winding portion 21 and a second winding portion 22 that are electrically insulated from each other. In other words, the first winding portion 21 and the second winding portion 22 are not directly electrically connected to each other. Figure 11 As illustrated, the first winding portion 21 and the second winding portion 22 may be, for example, a primary winding and a secondary winding, or, for example, a choke winding and a primary or secondary winding, or the like.

[0068] Here, the virtual line 26 shows that the first winding portion 21 and the second winding portion 22 are arranged in two lines, that is, they are wound together around the base 3. However, this is not necessary, and the first winding portion 21 and the second winding portion 22 can also be wound around the base 3 separately.

[0069] Furthermore, only radial winding layers 2.1-2.3 of the first winding portion 21 are inserted between the thread projections 6.1. In particular, only one radial winding layer 2.1 and only one longitudinal layer 2.6, 2.8 and 2.10 of the first winding portion 21 are inserted onto the thread base 6.2 between the thread projections 6.1.

[0070] Only the radial winding layers 2.2 and 2.3 of the second winding section 22 are radially stacked on the thread projections 6.1 of the threaded section 6. On the other hand, only the radial winding layers 2.2 and 2.3 of the first winding section 21 are radially stacked on the first radial winding layer 2.1 of the first winding section 21. In the non-threaded section 13, the radial winding layers 2.1, 2.2 and 2.3 of the first winding section 21 and the second winding section 22, in particular all of these radial winding layers, are stacked on the outer surface 4 of the base body 3.

[0071] It should be noted that the total number of radial winding layers 2.1-2.3 and / or the total number of longitudinal winding layers 2.4-2.13 is generally not limited to the embodiments described. In particular, it should be noted that the number of winding layers (in particular their total number of turns) can be varied, in particular for a specific application of the bobbin 1.

[0072] Now, the winding process will be described with respect to the first winding portion 21 and the second winding portion 22 and their bifilar arrangement.

[0073] exist Figure 3 , the start of the first winding portion 21 is denoted by reference numeral 27. Furthermore, the start of the second winding portion 22 is denoted by reference numeral 28. The end of the first winding portion 21 is denoted by reference numeral 29, and the end of the second winding portion 22 is denoted by reference numeral 30.

[0074] This shows that the winding process first starts by providing the first winding portion 21 in the threaded portion 6 ( Figure 3 At the end of the first pass (along the longitudinal axis 7) (indicated by the start 28 of the second winding portion 22), the first winding portion 21 and the second winding portion 22 then begin a second pass wound in a bifilar arrangement. Thus, each radial winding layer 2.1-2.3 is formed by winding the winding portions 21 and 22 once along the longitudinal axis 7. In other words, the winding process is repeated in two steps. Figure 3 Starting on the left, the winding moves to the right to form the first radial winding layer 2.1, then (at the top of the threaded portion 6) returns to the left to form the second radial winding layer 2.2, and then (at the top of the second radial winding layer 2.2) returns to the right to form the third and final radial winding layer 2.3. Thus, in this example, the first winding portion 21 has more turns than the second winding portion 22.

[0075] By providing this arrangement, the following exemplary advantages are achieved. First, by radially stacking the windings 2 as shown, and in particular stacking the second winding portion 22 on the thread projections 6.1, a significant reduction in the air-filled space is achieved compared to a case where no threaded portion 6 is provided, i.e., compared to a case where the outer surface 4 of the bobbin 1 is flat in cross-section. This significantly improves the cooling efficiency of the windings 2. Furthermore, this bobbin 1 provides for an efficient winding process because, for example, the number of turns of each winding portion 21 and 22 can be easily predetermined, in particular by determining the pitch 8 and / or the number and / or length of the threaded portions 6.

[0076] However, it should be noted that the winding process described here is not the same as Figure 3 The results shown are ideal. In practice, some upper radial winding layers 2.2–2.3 could slip, causing portions of second winding section 22 to (at least partially) rest on portions of first winding section 21, or vice versa, or portions of first winding section 21 to (at least partially) rest on projections 6.1. The advantageous configuration of threaded portion 6, on the other hand, reduces the likelihood of this occurring. Furthermore, even in this situation, threaded portion 6 ensures that first winding section 21 is securely held between threaded projections 6.1.

[0077] Now, refer to Figures 4 to 6 The second embodiment of the present invention is described. Figure 4 shows a schematic side view of a spool 1 according to a second embodiment of the invention, Figure 5 shows a perspective view of a spool 1 according to a second embodiment of the invention, Figure 6 A cross-sectional view of a spool 1 according to a second embodiment of the invention is shown.

[0078] as Figures 1 to 3 , this embodiment Figure 4 and Figure 5 Winding 2 is omitted for ease of illustration. Figure 6 The winding state of the bobbin 1 is shown. Here, Figure 6 Two radial halves of the spool 1 are shown (ie complete cross-sectional views). Figure 6 Two exemplary magnetic cores 31 inserted into the bobbin 1 are also shown.

[0079] The spool 1 in this embodiment comprises two non-threaded portions 13 , each located at one end 11 of the base body 3 along the longitudinal axis 7 .

[0080] Between the two non-threaded parts 13, the spool 1 includes a threaded part 6. Here, the threaded part 6 includes a single thread, namely two thread protrusions 6.1 and a thread base 6.2. Along the longitudinal axis 7, the threaded part 6 and the two non-threaded parts 13 each account for approximately one third of the length of the base body 3.

[0081] Here, the cross-sectional shape of the thread projection 6.1 in a plane parallel to the longitudinal axis 7 (e.g. in the radial direction 12 and the plane of the longitudinal axis 7) changes along the helical extension of the threaded portion 6. In particular, the cross-sectional shape changes gradually and continuously along the helical extension of the threaded portion 6.

[0082] In particular, the cross-sectional shape of the thread protrusion 6.1 gradually becomes smaller towards the end 14 of the thread protrusion 6.1. Therefore, during the winding process, damage to the winding 2, in particular damage to its insulation, can be prevented or reduced.

[0083] Now, reference Figure 6 The winding 2 of the bobbin 1 in this embodiment will be described.

[0084] As the thread protrusion 6.1 gradually becomes smaller, Figure 6 As shown, the threaded portion 6 in this embodiment continuously includes one thick thread protrusion 33 and two thin thread protrusions 34 along a circumferential direction 35 of the base body 3 perpendicular to the radial direction 12 and the longitudinal axis 7 .

[0085] In this embodiment, two thin thread protrusions 34 are defined as portions of the threaded portion 6 along the circumferential direction 35, wherein the cross-sectional width 37 of the thread protrusion 6.1 is smaller than the cross-sectional width 9 of the winding 2. Other portions of the threaded portion 6 along the circumferential direction 35 are defined as thick thread protrusions 33, wherein the cross-sectional width 37 is equal to or greater than the cross-sectional width 9 of the winding 2.

[0086] Here, the pitch 8, defined by the distance between the midpoints of the thread projections 6.1 along the longitudinal axis 7, is fixed where two adjacent thread projections 6.1 are present. In other words, the width of the thread base 6.2 along the longitudinal axis 7 is fixed along its helical extension.

[0087] Here, for example, only one winding portion 21 is provided. However, this embodiment can be appropriately combined with the above-described embodiment to provide two winding portions 21 and 22.

[0088] In this embodiment, only one radial winding layer 2.1 of winding 2 is inserted into threaded portion 6 between two thread projections 6.1, that is, between two thin thread projections 34. As described above, the cross-sectional shape of thread projection 6.1 varies along the helical extension of threaded portion 6. Here, the maximum cross-sectional width 37 of thread projection 6.1 (i.e., thick thread projection 33) is equal to or greater than the cross-sectional width 9 of winding 2, for example, approximately twice the cross-sectional width 9 of winding 2. Therefore, two longitudinal winding layers 2.8 and 2.9 of winding 2 are radially stacked on thread projection 6.1.

[0089] It should be noted that Figure 6 The asymmetrical winding configuration shown in (with the upper half clearly being wound more than the lower half) is simply due to the cross-section of the bobbin 1 shown. After all turns of a single radial winding layer (e.g. radial winding layer 2.1) are completed, winding 2 is transferred to the "next" radial winding layer (e.g. radial winding layer 2.2), making the winding appear asymmetrical in this cross-section.

[0090] In this embodiment, two magnetic cores 31 are inserted into the bobbin 1. Typically, an air gap 32 is provided between the two magnetic cores 31 along the longitudinal axis 7 to set the inductance value. Figure 6 As shown, a fringing magnetic field 36 is generated at the air gap 32 .

[0091] In this embodiment, threaded portion 6 is configured such that winding 2 is at least partially displaced along longitudinal axis 7, away from air gap 32. This reduces the effects of fringing magnetic fields 36 on winding 2, thereby also reducing its AC resistance. Furthermore, manufacturing is simplified, as winding 2 can be easily inserted into threaded portion 6, particularly through automated winding processes. Furthermore, the fill factor (i.e., the ratio of the winding-filled space to the air-filled space of bobbin 1) remains high, advantageously improving the cooling efficiency and overall size of bobbin 1.

[0092] Now, refer to Figures 7 to 9 The third embodiment of the present invention is described. Figure 7 shows a schematic side view of a spool 1 according to a third embodiment of the invention, Figure 8 shows a perspective view of a spool 1 according to a third embodiment of the invention, Figure 9 A cross-sectional view of a spool 1 according to a third embodiment of the invention is shown.

[0093] Similar to some parts of the above embodiments, Figure 7 and Figure 8 In the figure, the winding 2 is omitted for the convenience of explaining the base 3.

[0094] In this embodiment, similar to the second embodiment, the cross-sectional shape of the thread projection 6.1 changes along the helical extension of the threaded portion 6. In particular, the thread projection 6.1 tapers toward its end 14 along the longitudinal axis 7. Here, along the longitudinal axis 7, the two non-threaded portions 13 each comprise approximately one-quarter of the length of the base body 3, while the threaded portion 6 comprises approximately half the length of the base body 3.

[0095] like Figure 9 As shown, in this embodiment, the bobbin 1 includes three magnetic cores 31 , and two air gaps 32 are respectively formed between two adjacent magnetic cores 31 along the longitudinal axis 7 .

[0096] Similar to the second embodiment, in this embodiment, the AC resistance of the winding 2 is reduced by moving the winding 2 away from the fringe magnetic field 36 at the air gap 32. Figure 6 and Figure 9 As shown in the comparison results, the threaded portion 6 of this embodiment is longer along the longitudinal axis 7. Furthermore, by arranging the winding 2 within the threaded portion 6, the filling factor is advantageously kept high, thereby improving cooling and reducing the space required for the spool 1.

[0097] In some embodiments, the number of threaded sections 6 corresponds to the number of air gaps 32 formed between adjacent magnetic cores 31. In other words, if n air gaps 32 are provided, n threaded sections 6 are also provided. In this regard, a single threaded section 6 is defined as one continuous threaded section 6. Specifically, the plurality of threaded sections 6 are separated by non-threaded sections 13 therebetween.

[0098] Furthermore, in some embodiments, each threaded portion 6 is located radially outside each air gap 32. For example, if the air gap 32 is provided at the end 11 of the bobbin 1, the threaded portion 6 is also located at the end 11 of the bobbin 1.

[0099] Compared to providing a section at the air gap 32 where there is strictly no winding 2, for example, this embodiment has the advantage that the winding process is more efficient and in particular can be easily automated, in particular since a continuous winding process can be employed.

[0100] Figure 10 A perspective view of a spool 1 according to a fourth embodiment of the invention is shown.

[0101] In this embodiment, the bobbin 1 includes a plurality of base bodies 3.1 and 3.2, namely a first base body 3.1 and a second base body 3.2. In some embodiments, the plurality of base bodies 3.1 and 3.2 are integrally formed with each other.

[0102] Here, each of base bodies 3.1 and 3.2 includes a winding (not shown). The windings of base bodies 3.1 and 3.2 can be separate from each other, that is, insulated from each other, or they can be connected to each other, particularly in series. For example, in one embodiment, the winding wound around one base body 3.1 is a choke winding, while the winding wound around the other base body 3.2 is a primary or secondary winding. In particular, the winding of one base body 3.1 is connected in series with a winding section (e.g., the first winding section 21 described above) of the other base body 3.2.

[0103] Furthermore, in some embodiments, one or all of the plurality of base bodies 3 . 1 and 3 . 2 include a threaded portion 6 .

[0104] Figure 11 FIG. 1 is a schematic diagram showing a magnetic component 100 according to a fifth embodiment of the present invention.

[0105] The magnetic component 100 in this embodiment includes three bobbins 1 according to any of the above embodiments. Figure 11 The magnetic component 100 shown comprises three bobbins 1 according to the fourth embodiment, wherein each bobbin 1 comprises a first base body 3.1 and a second base body 3.2.

[0106] In this embodiment, the magnetic component 100 includes a winding 2 and a magnetic core 31 ( Figure 11 A three-phase transformer 101 is formed by a first winding section 21 of each bobbin 1, which is not visible in the figure. Here, the first winding section 21 of each bobbin 1 forms the primary winding of transformer 101, and the second winding section 22 of each bobbin 1 forms the secondary winding of transformer 101. Each bobbin 1 is part of a phase of three-phase transformer 101. In this example, first substrate 3.1 forms the choke of three-phase transformer 101. In some embodiments, windings 2 of substrate 3.1 are connected in series with first winding section 21 of their respective bobbin 1.

[0107] Through the above embodiments, the present application realizes a bobbin 1 that advantageously saves space while allowing for easy and efficient manufacturing and cooling. In addition, the above embodiments provide a magnetic component 100, in particular a transformer 101, having these advantages.

[0108] In addition to the above text description, please refer to Figures 1 to 11 , these drawings show configuration examples of the present application in detail.

Claims

1. A bobbin (1) for supporting an insulated winding (2), comprising: a base body (3) having an outer surface (4) around which the winding (2) is wound to define a winding axis (5); in The outer surface (4) comprises at least one threaded portion (6) spiraling along the longitudinal axis (7) of the base body (3), the threaded portion (6) defining one or more thread protrusions (6.1) and a thread base (6.2); The winding (2) comprises a plurality of radial winding layers (2.1, 2.2, 2.3) stacked in a radial direction (12) perpendicular to the winding axis (5), and At least one radial winding layer (2.1, 2.2, 2.3) is inserted into the at least one threaded portion (6).

2. The bobbin (1) according to claim 1, wherein one longitudinal winding layer (2.4-2.13) of the winding (2) is inserted between two thread protrusions (6.1) of the threaded portion (6).

3. The bobbin (1) according to claim 2, wherein the pitch (8) of the threaded portion (6) is equal to or greater than the cross-sectional diameter (9) of the winding (2) and less than twice the cross-sectional diameter (9) of the winding (2).

4. The spool (1) according to claim 1, wherein the outer surface (4) of the base body (3) comprises at least one non-threaded portion (13) at an end (14) of the threaded portion (6) along the longitudinal axis (7).

5. The bobbin (1) according to claim 4, wherein at least two longitudinal winding layers (2.4-2.13) of the winding (2) are inserted into a corresponding one of the non-threaded portions (13).

6. The bobbin (1) according to claim 1, wherein at least one radial winding layer (2.1, 2.2, 2.3) is radially stacked on at least one thread protrusion (6.1) of the threaded portion (6).

7. The spool (1) according to claim 1, wherein the pitch (8) of the threaded portion (6) remains fixed along the longitudinal axis (7) of the base body (3).

8. The spool (1) according to claim 1, wherein the cross-sectional shape of the threaded protrusion (6.1) in a plane parallel to the longitudinal axis (7) remains constant along the spiral extension of the threaded portion (6) or gradually decreases towards at least one end (14) of the threaded protrusion.

9. The bobbin (1) according to claim 1, wherein the winding (2) comprises a first winding portion (21) and a second winding portion (22) which are electrically insulated from each other.

10. The bobbin (1) according to claim 9, wherein only the radial winding layers (2.1, 2.2, 2.3) of the first winding section (21) of the winding (2) are inserted into the threaded section (6).

11. The bobbin (1) according to claim 10, wherein only the radial winding layers (2.1, 2.2, 2.3) of the second winding section (22) of the winding (2) are radially stacked on at least one thread projection (6.1) of the threaded section (6).

12. The bobbin (1) according to claim 11, wherein the first winding portion (21) and the second winding portion (22) are at least partially in a bifilar arrangement.

13. The bobbin (1) according to claim 12, wherein in a first radial winding layer (2.1), the first winding portion (21) is inserted into the threaded portion (6); and in at least one further radial winding layer (2.2, 2.3), the first winding portion (21) and the second winding portion (22) are arranged in a bifilar arrangement such that the second winding portion (22) is radially stacked on the threaded protrusion (6.1) and such that the first winding portion (21) is radially stacked on the first winding portion (21) of the first radial winding layer (2.1).

14. A magnetic component (100) comprising at least one spool (1) according to claim 1.

15. The magnetic component (100) according to claim 14, wherein the winding (2) comprises a first winding portion (21) and a second winding portion (22) which are electrically insulated from each other; The magnetic component (100) comprises a transformer (101), the first winding portion (21) is a part of a primary winding of the transformer (101), and the second winding portion (22) is a part of a secondary winding of the transformer (101).

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