Transformer structure
By adopting an interleaved winding structure in the transformer and utilizing C-shaped connections and gap design, the problems of large winding space occupation and high cost are solved, realizing the miniaturization and cost savings of the transformer.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-11
- Publication Date
- 2026-03-13
AI Technical Summary
In the existing technology, transformers with interleaved windings occupy a large amount of circuit board space when connected in series, which makes circuit design and assembly difficult, increases manufacturing costs, and is not conducive to product miniaturization.
The staggered winding structure is adopted. By setting the first and second windings on the core unit, the winding segments are arranged along the central axis using C-shaped connectors, and gaps are formed between the winding segments to embed another winding, reducing the number of substrate contacts and saving space and cost.
This technology enables the miniaturization of transformers, reduces manufacturing costs, simplifies the coil series structure, and reduces the space occupied on the circuit board.
Smart Images
Figure CN121662569A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a transformer structure. More specifically, this invention relates to a transformer structure having interleaved windings. Background Technology
[0002] When connecting the coils in the interleaved windings inside a transformer in series, it is usually necessary to connect the ends of different coils to a circuit board and then connect the different coils in series electrically through the circuit board.
[0003] However, this approach not only easily occupies the circuit layout space on the circuit board, leading to difficulties in circuit design and assembly, but also increases manufacturing costs and is not conducive to product miniaturization.
[0004] In view of this, designing a transformer structure with interleaved windings and simplifying its coil series structure has become a challenge for researchers in this field. Summary of the Invention
[0005] The purpose of this invention is to provide a transformer structure to solve at least one of the above-mentioned problems.
[0006] In view of the aforementioned known problems, one embodiment of the present invention provides a transformer structure, including a core unit, a first winding, and a second winding. The core unit has a central shaft, the first winding is disposed in the core unit, and has a first low-winding segment, a first high-winding segment, and a first connecting portion, wherein the first connecting portion connects the first low-winding segment and the first high-winding segment, and a first gap is formed between the first low-winding segment and the first high-winding segment.
[0007] The aforementioned second winding is disposed in the aforementioned core unit and has a second low winding segment, a second high winding segment and a second connecting portion, wherein the aforementioned second connecting portion connects the aforementioned second low winding segment and the aforementioned second high winding segment, and a second gap is formed between the aforementioned second low winding segment and the aforementioned second high winding segment.
[0008] The aforementioned second low-wound segment is disposed within the aforementioned first gap, and the aforementioned first high-wound segment is disposed within the aforementioned second gap, so that the aforementioned first low-wound segment, the aforementioned second low-wound segment, the aforementioned first high-wound segment, and the aforementioned second high-wound segment are arranged sequentially along the aforementioned central axis direction.
[0009] In one embodiment, the aforementioned transformer structure is disposed on a substrate, and the aforementioned first winding further has two first ends, and the aforementioned first ends pass through the aforementioned substrate, wherein the aforementioned first ends are respectively connected to the aforementioned first low winding segment and the aforementioned first high winding segment.
[0010] In one embodiment, the aforementioned second winding further has two second ends, which pass through the aforementioned substrate and are respectively connected to the aforementioned second low-winding segment and the aforementioned second high-winding segment, wherein the aforementioned first end and the aforementioned second end are located on opposite sides of the aforementioned core unit.
[0011] In one embodiment, the aforementioned first connecting portion is bent around a horizontal axis to form a C-shaped structure, and the aforementioned horizontal axis is perpendicular to the aforementioned central axis.
[0012] In one embodiment, the aforementioned first low-winding segment, the aforementioned first high-winding segment, the aforementioned second low-winding segment, and the aforementioned second high-winding segment are all elliptical, and a portion of the aforementioned core unit passes sequentially through the aforementioned first low-winding segment, the aforementioned second low-winding segment, the aforementioned first high-winding segment, and the aforementioned second high-winding segment along the aforementioned central axis direction.
[0013] In one embodiment, the aforementioned first winding and the aforementioned second winding are flat copper wires.
[0014] Another embodiment of the present invention provides a transformer structure, including a core unit, a first winding, and a second winding. The core unit has a central shaft, the first winding is disposed in the core unit, and has a first low-winding segment, a first high-winding segment, and a first connecting portion, wherein the first connecting portion has a C-shaped structure and connects the first low-winding segment and the first high-winding segment, and a gap is formed between the first low-winding segment and the first high-winding segment.
[0015] The aforementioned second winding is disposed in the aforementioned core unit and in the aforementioned gap, so that the aforementioned first low winding segment, the aforementioned second winding and the aforementioned first high winding segment are arranged sequentially along the aforementioned central axis direction.
[0016] In one embodiment, the aforementioned first low-winding segment and the aforementioned first high-winding segment are circular, and a portion of the aforementioned core unit sequentially passes through the aforementioned first low-winding segment, the aforementioned second winding, and the aforementioned first high-winding segment along the aforementioned central axis direction.
[0017] In one embodiment, the first winding is a flat copper wire, and the second winding is a multi-strand wire. Attached Figure Description
[0018] Figure 1 A perspective view showing the structure of a transformer according to an embodiment of the present invention.
[0019] Figure 2 express Figure 1 Another perspective view of the transformer structure shown.
[0020] Figure 3express Figure 1 and Figure 2 An exploded view of the transformer structure in the image.
[0021] Figure 4 express Figures 1-3 A three-dimensional view of the first winding before it is formed.
[0022] Figure 5 express Figures 1-3 Exploded view of the first and second windings before assembly.
[0023] Figure 6 express Figures 1-3 The first and second windings are shown in a three-dimensional view after assembly.
[0024] Figure 7 A perspective view showing the transformer structure according to another embodiment of the present invention.
[0025] Figure 8 express Figure 7 An exploded view of the transformer structure in the image.
[0026] Figure 9 express Figure 7 A cross-sectional view of the transformer structure.
[0027] Figure 10 express Figures 7-9 A three-dimensional view of the first winding before it is formed.
[0028] Figure 11 express Figure 10 The first winding in the process is shown in a three-dimensional diagram after it has been formed.
[0029] Figure 12 express Figure 10 The first winding in the process is shown in a three-dimensional view from another perspective after it has been formed.
[0030] The attached figures are labeled as follows:
[0031] 100: Transformer Structure
[0032] 200: Transformer Structure
[0033] A1: Horizontal axis
[0034] A2: Horizontal axis
[0035] B:Substrate
[0036] C1: First winding
[0037] C11: First low-winding segment
[0038] C12: First high-winding segment
[0039] C13: First connecting part
[0040] C2: Second winding
[0041] C21: Second low-winding segment
[0042] C22: Second high-winding segment
[0043] C23: Second connecting part
[0044] F: Core unit
[0045] F1: Magnetic conductive component
[0046] F2: Magnetic conductive component
[0047] FA: Central axis
[0048] P11: First end
[0049] P12: First end
[0050] P21: Second end
[0051] P22: Second end
[0052] S1: First gap
[0053] S2: Second gap
[0054] S3: Gap Detailed Implementation
[0055] The following describes the transformer structure according to an embodiment of the present invention. However, it will be readily apparent that the embodiments of the present invention provide many suitable inventive concepts and can be implemented in a wide range of specific contexts. The specific embodiments disclosed are merely illustrative of the use of the invention in a particular manner and are not intended to limit the scope of the invention.
[0056] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by those skilled in the art to which this disclosure pertains. It is understood that these terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the relevant art and the background or context of this disclosure, and should not be interpreted in an idealized or overly formal manner, unless specifically defined herein.
[0057] The foregoing and other technical contents, features, and effects of the present invention will be clearly presented in the following detailed description of a preferred embodiment with reference to the accompanying drawings. The directional terms mentioned in the following embodiments, such as up, down, left, right, front, or back, are only for reference to the directions in the accompanying drawings. Therefore, the directional terms used in the embodiments are for illustrative purposes and not for limiting the present invention.
[0058] Please refer to the following first: Figure 1 , Figure 2 , Figure 3 and Figure 4 ,in Figure 1 A perspective view showing a transformer structure 100 according to an embodiment of the present invention. Figure 2 express Figure 1 Another perspective view of the transformer structure 100 shown. Figure 3 express Figure 1 and Figure 2 Exploded view of transformer structure 100 in the image.
[0059] like Figure 1 , Figure 2 and Figure 3 As shown, a transformer structure 100 according to an embodiment of the present invention has interleaved windings inside, which mainly includes an iron core unit F, a first winding C1 and a second winding C2, and the transformer structure 100 is disposed on a substrate B.
[0060] In this embodiment, the aforementioned first winding C1 and second winding C2 are respectively integrally formed and wound from flat copper wire, and the aforementioned core unit F is composed of two magnetically conductive components F1 and F2 with E-shaped structures. Figure 3 Specifically, the central portions of the aforementioned magnetic conductive components F1 and F2 will pass through the aforementioned first winding C1 and second winding C2 after assembly, and the two first ends P11 and P12 of the aforementioned first winding C1 and the two second ends P21 and P22 of the aforementioned second winding C2 will pass through the substrate B after assembly, thereby fixing the aforementioned first winding C1 and second winding C2 on the substrate B.
[0061] It should be understood that the first ends P11 and P12 of the first winding C1 and the second ends P21 and P22 of the second winding C2 are located on the opposite side of the core unit F, and the first winding C1 and the second winding C2 can be connected to an external circuit (not shown) through the first ends P11 and P12 and the second ends P21 and P22, respectively.
[0062] Specifically, the aforementioned first winding C1 and second winding C2 are coupled to the core unit F, that is, the first winding C1 and second winding C2 are disposed in the core unit F, wherein the aforementioned first winding C1 has a first low winding segment C11, a first high winding segment C12 and a first connecting part C13.
[0063] The aforementioned first connecting part C13 has a C-shaped structure for connecting the first low-winding segment C11 and the first high-winding segment C12, so that the aforementioned first low-winding segment C11 and the first high-winding segment C12 can be connected along the central axis FA of the core unit F. Figure 3 The windings are arranged in an directional manner, and a gap can be formed between the first low-winding segment C11 and the first high-winding segment C12 to accommodate at least a portion of the second winding C2, thereby forming an interleaved winding.
[0064] Similarly, the aforementioned second winding C2 has a second low-winding segment C21, a second high-winding segment C22, and a second connecting portion C23, wherein the aforementioned second connecting portion C23 has a C-shaped structure for connecting the second low-winding segment C21 and the second high-winding segment C22.
[0065] In this way, the aforementioned second low-winding segment C21 and second high-winding segment C22 can travel along the central axis FA of the core unit F. Figure 3 The windings are arranged in a directional manner, and a gap is formed between the first low-winding segment C21 and the second high-winding segment C22 to accommodate at least a portion of the first winding C1, thereby forming an interleaved winding.
[0066] Please refer to the following as well. Figure 4 , Figure 5 and Figure 6 , Figure 4 express Figures 1-3 A three-dimensional view of the first winding C1 before forming. Figure 5 express Figures 1-3 Exploded view of the first winding C1 and the second winding C2 before assembly. Figure 6 express Figures 1-3 The first winding C1 and the second winding C2 are shown in a three-dimensional view after assembly.
[0067] like Figure 4 As shown, the aforementioned first winding C1 is mainly composed of flat copper wire. During manufacturing, the flat copper wire can first be wound by a winding machine to form the aforementioned first low-winding segment C11 and first high-winding segment C12 with elliptical structures; then, the first connecting part C13 between the first low-winding segment C11 and the first high-winding segment C12 can be bent around a horizontal axis A1 (for example...). Figure 4 (As indicated by the arrow in the image), thereby bending the aforementioned connecting part C13 into a C-shaped structure (as shown by the arrow in the image). Figure 5 and Figure 6 (As shown).
[0068] In this way, the aforementioned first low-winding segment C11 and first high-winding segment C12 can be wound along the central axis FA of the core unit F. Figure 3The wires are arranged in a directional direction, and a first gap S1 can be formed between the first low-winding segment C11 and the first high-winding segment C12. Figure 5 ).
[0069] In this embodiment, the aforementioned second winding C2 is also composed of flat copper wire. During manufacturing, the flat copper wire can first be wound by a winding machine to form the aforementioned second low winding segment C21 and second high winding segment C22 with elliptical structures; then, the second connecting portion C23 between the second low winding segment C21 and the second high winding segment C22 can be bent, thereby bending the aforementioned connecting portion C23 into a C-shaped structure (e.g., Figure 5 (As shown).
[0070] In this way, the aforementioned second low-winding segment C21 and second high-winding segment C22 can travel along the central axis FA of the core unit F. Figure 3 The wires are arranged in a directional direction, and a second gap S2 can be formed between the aforementioned second low-winding segment C21 and the second high-winding segment C22. Figure 5 ).
[0071] from Figure 6 As can be seen, the aforementioned first winding C1 and second winding C2 are embedded in each other and together form an interleaved winding. The second low winding segment C21 below the second winding C2 is embedded in the first gap S1 of the first winding C1 during assembly, while the first high winding segment C12 above the first winding C1 is embedded in the second gap S2 of the second winding C2 during assembly.
[0072] With the aforementioned configuration, the first low-winding segment C11, the second low-winding segment C21, the first high-winding segment C12, and the second high-winding segment C22 can be arranged sequentially along the central axis FA direction (Z-axis direction) of the core unit F. Since the first low-winding segment C11 and the first high-winding segment C12 are connected in series with each other through the C-shaped first connecting part C13, they can be connected to the external circuit by using the first ends P11 and P12 of the first winding C1. This reduces the number of contacts of the winding on the substrate B and saves space and manufacturing costs. It also facilitates the miniaturization of the product.
[0073] Similarly, since the second low-winding segment C21 and the second high-winding segment C22 are connected in series with each other through the second connecting part C23, they can be connected to the external circuit by using the second ends P21 and P22 of the second winding C2. This reduces the number of contacts of the winding on the substrate B and saves space and manufacturing costs. It also helps to miniaturize the product.
[0074] Please refer to the following as well. Figure 7 , Figure 8 and Figure 9 , Figure 7A perspective view showing a transformer structure 200 according to another embodiment of the present invention. Figure 8 express Figure 7 Exploded view of transformer structure 200 in the image. Figure 9 express Figure 7 A cross-sectional view of the transformer structure 200 in the image.
[0075] like Figures 7-9 As shown, another embodiment of the transformer structure 200 of the present invention and Figures 1-3 The main difference between transformer structure 100 and the previous one is: Figures 7-9 The first winding C1 of the transformer structure 200 is made of flat copper wire, while the second winding C2 is made of multi-strand wire. The first winding C1 has a circular first low winding segment C11 and a first high winding segment C12. The second winding C2 is sandwiched between the first low winding segment C11 and the first high winding segment C12, thus forming an interleaved winding.
[0076] Please refer to the following as well. Figure 10 , Figure 11 and Figure 12 , Figure 10 express Figures 7-9 A three-dimensional view of the first winding C1 before forming. Figure 11 express Figure 10 The first winding C1 in the figure is shown in a three-dimensional diagram after it has been formed. Figure 12 express Figure 10 A three-dimensional view of the first winding C1 after it has been formed, from another perspective.
[0077] like Figure 10 As shown, the aforementioned first winding C1 is mainly composed of a flat copper wire. During manufacturing, the flat copper wire can first be wound by a winding machine to form a first low-winding segment C11 and a first high-winding segment C12 with a circular structure; then, the first connecting part C13 between the first low-winding segment C11 and the first high-winding segment C12 can be bent around a horizontal axis A2 (as shown). Figure 10 (As indicated by the arrow in the image), thereby bending the aforementioned connecting part C13 into a C-shaped structure (as shown by the arrow in the image). Figure 11 and Figure 12 (As shown).
[0078] In this way, the aforementioned first low-winding segment C11 and first high-winding segment C12 can be wound along the central axis FA of the core unit F. Figure 8 The wires are arranged in a directional direction, and a gap S3 can be formed between the first low-winding segment C11 and the first high-winding segment C12. Figure 12 ).
[0079] As mentioned above, since the first low-winding segment C11 and the first high-winding segment C12 are connected in series with each other through the C-shaped first connecting part C13, they can be connected to the external circuit by using the first ends P11 and P12 of the first winding C1. This reduces the electrical contacts of the winding on the substrate (not shown) to save space and manufacturing costs, and also facilitates the miniaturization of the product.
[0080] It should be noted that the second winding C2 in this embodiment is a multi-strand wire. During assembly, the second winding C2 can be sandwiched between the first low winding segment C11 and the first high winding segment C12 to form an interleaved winding. However, the aforementioned second winding C2 can also be made of flat copper wire or other forms of winding, and is not limited to those disclosed in the embodiments of this invention.
[0081] While the embodiments and advantages of the present invention have been disclosed above, it should be understood that those skilled in the art can make modifications, substitutions, and refinements without departing from the spirit and scope of the invention. Furthermore, the scope of protection of the present invention is not limited to the processes, machines, manufacturing methods, material compositions, apparatuses, methods, and steps described in the specific embodiments of the specification. Any processes, machines, manufacturing methods, material compositions, apparatuses, methods, and steps currently or in the future that can be developed from the disclosure of this invention can be used according to the present invention, as long as they can perform substantially the same function or obtain substantially the same results in the embodiments described herein. Therefore, the scope of protection of the present invention includes the aforementioned processes, machines, manufacturing methods, material compositions, apparatuses, methods, and steps. In addition, each claim constitutes an individual embodiment, and the scope of protection of the present invention also includes combinations of the various claims and embodiments.
[0082] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Those skilled in the art can make some modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.
Claims
1. A transformer structure, comprising: A single iron core unit has a central axis; A first winding is disposed in the core unit and has a first low-winding segment, a first high-winding segment, and a first connecting portion, wherein the first connecting portion connects the first low-winding segment and the first high-winding segment, and a first gap is formed between the first low-winding segment and the first high-winding segment; and A second winding is disposed in the core unit and has a second low winding segment, a second high winding segment and a second connecting portion, wherein the second connecting portion connects the second low winding segment and the second high winding segment, and a second gap is formed between the second low winding segment and the second high winding segment. The second low-wound segment is disposed within the first gap, and the first high-wound segment is disposed within the second gap, so that the first low-wound segment, the second low-wound segment, the first high-wound segment, and the second high-wound segment are arranged sequentially along the central axis.
2. The transformer structure as claimed in claim 1, wherein the transformer structure is disposed on a substrate, the first winding further having two first ends, and the two first ends passing through the substrate, wherein the two first ends are respectively connected to the first low-winding segment and the first high-winding segment.
3. The transformer structure as claimed in claim 2, wherein the second winding further has two second ends, a plurality of second ends passing through the substrate and respectively connecting the second low-winding segment and the second high-winding segment, wherein the two first ends and the two second ends are located on opposite sides of the core unit.
4. The transformer structure as claimed in claim 1, wherein the first connecting portion is bent around a horizontal axis to form a C-shaped structure, and the horizontal axis is perpendicular to the central axis.
5. The transformer structure as described in claim 1, wherein the first low-winding segment, the first high-winding segment, the second low-winding segment, and the second high-winding segment are all elliptical, and a portion of the core unit passes sequentially through the first low-winding segment, the second low-winding segment, the first high-winding segment, and the second high-winding segment along the central axis.
6. The transformer structure as described in claim 1, wherein the first winding is an integrally formed flat copper wire, and the second winding is an integrally formed flat copper wire.
7. A transformer structure, comprising: A single iron core unit has a central axis; A first winding is disposed in the core unit and has a first low-winding segment, a first high-winding segment, and a first connecting portion, wherein the first connecting portion connects the first low-winding segment and the first high-winding segment, and a gap is formed between the first low-winding segment and the first high-winding segment; and A second winding is disposed within the gap, such that the first low-winding segment, the second winding, and the first high-winding segment are arranged sequentially along the central axis.
8. The transformer structure as claimed in claim 7, wherein the first low-winding segment and the first high-winding segment are circular, and a portion of the core unit sequentially passes through the first low-winding segment, the second winding, and the first high-winding segment along the central axis.
9. The transformer structure as claimed in claim 7, wherein the first connection portion has a C-shaped structure, and the first winding is an integrally formed flat copper wire.
10. The transformer structure as claimed in claim 7, wherein the second winding is a multi-strand wire.