Power supply device including transformer

Abstract

A power supply device according to an embodiment includes: a core unit including an upper core and a lower core disposed to the upper core in a first direction; a coil unit having a portion accommodated between the upper core and the lower core and including a plurality of terminals protruding in a second direction; the insulating plate is provided with a plurality of through holes for the plurality of terminals to pass through; and a bus bar disposed on the insulating plate.

Description

Technical Field

[0001] The embodiments relate to a power supply device including a transformer. Background Technology

[0002] Various coil components, such as transformers or line filters, are installed in the power supply units of electronic devices.

[0003] Transformers can be integrated into electronic devices for a variety of purposes. For example, transformers can be used to transfer energy from one circuit to another. Furthermore, transformers can be used to change the magnitude of voltage, such as stepping up or stepping down. Moreover, because transformers provide an inductive connection only between the primary and secondary windings, rather than forming a direct current path, they can also be used to block direct current during AC transmission or to electrically isolate two circuits. Research to improve transformer performance is ongoing. Summary of the Invention

[0004] [Technical Issues]

[0005] An embodiment provides a power supply device including a transformer with excellent performance.

[0006] [Technical Solution]

[0007] The power supply device according to an embodiment may include: a core unit including an upper core and a lower core disposed facing the upper core in a first direction; a coil unit partially housed between the upper and lower cores, the coil unit including a plurality of terminals projecting in a second direction; an insulating plate including a plurality of through holes formed to allow a plurality of terminals to pass through respectively; and a busbar disposed on the insulating plate.

[0008] In one example, an insulating plate may be placed between the core unit and the busbar.

[0009] In one example, the insulating plate may be spaced apart from the core cell in the second direction.

[0010] In one example, the spacing in the second direction is greater than 0 and less than or equal to 3.5 mm.

[0011] In one example, the busbar may come into contact with the second surface of the insulating plate.

[0012] In one example, the busbar and the insulating plate may be at least partially spaced apart from each other.

[0013] In one example, the spacing between the busbar and the insulating plate can be smaller than the spacing between the insulating plate and the core unit.

[0014] In one example, at least a portion of the insulating plate may overlap with the core unit in the second direction.

[0015] In one example, the first thickness of the insulating plate in the second direction may be less than the second thickness of the busbar in the second direction.

[0016] In one example, the coil unit may include: a first coil unit configured to surround the central leg of the core unit; and a second coil unit disposed on at least a portion of the inner and outer sides of the first coil unit. The second coil unit may include: an inner coil unit disposed on at least a portion of the inner side of the first coil unit; and an outer coil unit disposed on at least a portion of the outer side of the first coil unit. The inner coil unit may include: an inner upper coil unit disposed on the upper portion of the inner side of the first coil unit; and an outer lower coil unit disposed on the lower portion of the inner side of the first coil unit. The outer coil unit may include: an outer upper coil unit disposed on the upper portion of at least a portion of the outer side of the first coil unit; and an outer lower coil unit disposed on the lower portion of at least a portion of the outer side of the first coil unit. The inner upper coil unit may include: a first body disposed on the upper portion of the inner side of the first coil unit; and a first terminal protruding from an upper end of the first body in a first direction intersecting the vertical direction. The internal lower coil unit may include: a second body disposed on the lower portion inside the first coil unit; and a second terminal protruding from a lower end of the second body in a first direction. The external upper coil unit may include: a third body disposed on the upper side of at least a portion outside the first coil unit; and a third terminal protruding from the third body in a first direction. The external lower coil unit may include: a fourth body disposed on the lower side of at least a portion outside the first coil unit; and a fourth terminal protruding from the fourth body in a first direction. Multiple terminals may include first to fourth terminals.

[0017] In one example, the first terminal and the second terminal may face each other vertically, and the third terminal and the fourth terminal may face each other vertically.

[0018] In one example, the through holes of the insulating plate may include: a first through hole formed to allow a first terminal to pass through, a second through hole formed to allow a second terminal to pass through, a third through hole formed to allow a third terminal to pass through, and a fourth through hole formed to allow a fourth terminal to pass through.

[0019] In one example, the busbar may include fifth to eighth through holes corresponding to the first to fourth through holes respectively, and the first to fourth terminals passing through the first to fourth through holes may be respectively disposed in the fifth to eighth through holes.

[0020] [Beneficial Effects]

[0021] In the power supply device including a transformer according to the embodiment, each busbar can be fixed as a whole, which can reduce the defect rate and improve the flatness of the busbar during assembly. The power supply device can be manufactured without the use of additional fixtures, spools or structural components, and the transformer and busbars can be cooled more quickly. Attached Figure Description

[0022] Figure 1 This is a front perspective view of a transformer according to an embodiment.

[0023] Figure 2 for Figure 1 The transformer shown is a rear-view perspective view.

[0024] Figure 3 for Figure 1 The diagram shows a front-view perspective of the transformer after the core unit has been removed.

[0025] Figure 4 for Figure 1 A three-dimensional view of the lower core in the core unit shown.

[0026] Figure 5a and Figure 5b They are respectively Figure 1 The diagram shows the three-dimensional and two-dimensional views of the first coil unit.

[0027] Figure 6a and Figure 6b They are respectively Figure 1 The diagram shows the three-dimensional and two-dimensional views of the internal coil unit.

[0028] Figure 7a and Figure 7b They are respectively Figure 1 The external coil unit is shown in both a 3D and a 2D view.

[0029] Figure 8a and Figure 8b The figures shown are a plan view and a partial side view of the power supply device according to an embodiment.

[0030] Figure 9 This is a schematic diagram illustrating the airflow speed when the fan shown in Figure 8 is running.

[0031] Figure 10a and Figure 10b These are schematic sectional views and connection sectional views of a power supply device according to another embodiment.

[0032] Figures 11a to 11d They are respectively Figure 10a and Figure 10b Exploded perspective view, connected perspective view, side view and plan view of an embodiment of the power supply device shown.

[0033] Figure 11e for Figure 10a The diagram shows the connection of the power supply unit after busbar 300 has been removed. Detailed Implementation

[0034] The present disclosure will now be described in more full with reference to the accompanying drawings, which illustrate various embodiments. However, the examples described may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. It should be understood that this disclosure covers all modifications, equivalent substitutions, and alternatives falling within the scope and spirit of this disclosure.

[0035] Although ordinal numbers such as "first" and "second" can be used to describe various components, they are not intended to limit the components. Such expressions are only used to distinguish one component from another. For example, without departing from the scope of this disclosure, a second element may be referred to as a first element, and similarly, a first element may be referred to as a second element. The term "and / or" as used herein includes any and all combinations of one or more of the relevant listed items.

[0036] It should be understood that when a component is said to be "connected" or "linked" to another component, it can be directly connected or linked to the other component, or there may be an intermediate component. Conversely, when a component is said to be "directly connected" or "directly linked" to another component, there is no intermediate component.

[0037] In the description of the embodiments, it should be understood that when an element (such as a layer (film), region, pattern, or structure) is referred to as being "on" or "below" another element (such as a substrate, layer (film), region, pad, or pattern), the terms "on" or "below" indicate that the element is directly located on or below the other element, or is indirectly disposed with an intermediate element present. It should also be understood that the standard for "on" or "below" is based on the accompanying drawings. Furthermore, for clarity and convenience, the thickness or dimensions of layers (films), regions, patterns, or structures shown in the drawings may be exaggerated, omitted, or schematically depicted, and may not accurately reflect actual dimensions.

[0038] The terminology used herein is for describing particular embodiments only and is not intended to limit the exemplary embodiments of this disclosure. Unless the context clearly indicates otherwise, the singular forms used herein are also intended to include the plural forms. It should also be understood that the terms “comprising” or “having” as used herein mean the presence of the stated feature, integer, step, operation, element, component, or combination thereof, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

[0039] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art. Terms defined in general dictionaries shall be interpreted as having the same meaning as they have in the relevant technical field, and shall not be interpreted as having an idealized or overly formal meaning unless expressly defined in this specification.

[0040] The embodiments will be described in detail below with reference to the accompanying drawings. Even when shown in different drawings, the same or equivalent elements are referred to by the same reference numerals, and redundant descriptions will be omitted.

[0041] Furthermore, some embodiments will be described using a Cartesian coordinate system (x-axis, y-axis, z-axis). In the Cartesian coordinate system, the x-axis, y-axis, and z-axis shown in the figures are orthogonal to each other, but the embodiments are not limited to this. The x-axis, y-axis, and z-axis may also intersect at an angle. For ease of description, the x-axis direction will be referred to as the first direction, the y-axis direction as the second direction, and the z-axis direction as the third direction. However, the first to third directions in the claims do not necessarily correspond to the x-axis, y-axis, and z-axis; they are merely used to distinguish directions.

[0042] The transformer according to an embodiment will be described below with reference to the accompanying drawings.

[0043] Figure 1 This is a front perspective view of the transformer 100 according to an embodiment. Figure 2 for Figure 1 The rear-view perspective view of transformer 100 is shown. Figure 3 for Figure 1 The diagram shown is a front perspective view of the transformer 100 after the core unit 110 has been removed. Figure 4 for Figure 1 A perspective view of the lower core 114 in the core unit 110 shown. Figure 5a and Figure 5b They are respectively Figure 1 The first coil unit 120 is shown in a three-dimensional view and a plan view. Figure 6a and Figure 6b They are respectively Figure 1 The three-dimensional and plan views of the internal coil unit 130 are shown. Figure 7a and Figure 7b They are respectively Figure 1 The external coil unit 140 is shown in a perspective view and a plan view.

[0044] Reference Figures 1 to 7b The transformer 100 according to the embodiment may include a core unit 110 and a coil unit.

[0045] The core unit 110 may possess magnetic circuit characteristics and can serve as a path for magnetic flux. The core unit 110 may include an upper core 112 and a lower core 114. Figure 4Only the lower core 114 is shown, but the upper core 112 and... Figure 4 Since the lower core 114 shown has the same shape, the following description of the lower core 114 also applies to the upper core 112.

[0046] The lower core 114 can be configured to be positioned above the upper core 112 in a third direction (i.e., the vertical direction) and connected to the upper core 112. The two cores 112 and 114 can be symmetrical or asymmetrical relative to each other in the vertical direction. However, for ease of description, the following description will assume that the two cores are symmetrical relative to each other in the vertical direction.

[0047] The upper core 112 and the lower core 114 may each include a flat body portion BO and a plurality of legs that project upward from the body portion BO in a third direction and extend in a predetermined direction. The plurality of legs may include two outer legs OL1 and OL2 spaced apart from each other in one axial direction (such as a second direction) and extending in another axial direction (such as a first direction) in the plan view, and a central leg CL disposed between the two outer legs OL1 and OL2. As described above, the two outer legs (i.e., the first outer leg OL1 and the second outer leg OL2) may be spaced apart in the second direction, and the central leg CL may be disposed between the first outer leg OL1 and the second outer leg OL2.

[0048] When the upper core 112 and the lower core 114 are connected to each other in the vertical direction, the outer leg and the center leg of the upper core 112 face the outer leg and the center leg of the lower core 114, respectively. In this case, a gap of a predetermined distance (e.g., 10 μm to 200 μm, but not limited thereto) can be formed between at least one pair of the pairs of outer legs and the pairs of center legs facing each other. Figure 1 and Figure 2 The embodiment shows a construction with a gap of 0, but the specific size of the gap is not limited.

[0049] Furthermore, the upper core 112 and the lower core 114 may each be made of magnetic materials, such as iron or ferrite, but this disclosure is not limited thereto.

[0050] Meanwhile, the coil unit can be at least partially accommodated between the upper core 112 and the lower core 114.

[0051] The coil unit according to the embodiment will be described in detail below.

[0052] According to an embodiment, the coil unit may include a first coil unit 120 and second coil units 130, 140.

[0053] The first coil unit 120 is a wound coil and may be at least partially disposed inside the core unit 110. The first coil unit 120 may be configured to surround the center leg CL, in which case the first coil unit 120 may include a through hole TH formed at the center of the first coil unit 120. The second coil unit 130 and the inner coil frame IB may be disposed in the through hole TH, through which the center leg CL may pass.

[0054] Reference Figure 5b The outer side 120OS of the first coil unit 120 may include the first to fourth outer sides SS1, SS2, SS3 and SS4.

[0055] The first outer surface SS1 and the second outer surface SS2 are arranged opposite to each other in the first direction.

[0056] The third outer side SS3 is located between the first outer side SS1 and the second outer side SS2, and the fourth outer side SS4 is arranged opposite to the third outer side SS3 in the second direction intersecting the first direction.

[0057] Meanwhile, according to the embodiment, the second coil units 130 and 140 may be at least partially disposed inside the core unit 110, that is, the second coil units 130 and 140 are respectively disposed on at least a portion of the inner side 120IS and the outer side 120OS of the first coil unit 120.

[0058] The second coil unit may include an internal coil unit 130 and an external coil unit 140.

[0059] The inner coil unit 130 is disposed on at least a portion of the inner side 120IS of the first coil unit 120, and the outer coil unit 140 is disposed on at least a portion of the outer side 120OS of the first coil unit 120.

[0060] The internal coil unit 130 may include an internal upper coil unit 132 and an internal lower coil unit 134 disposed vertically relative to each other. The internal upper coil unit 132 is disposed on the upper part of the inner side 120IS of the first coil unit 120, and the internal lower coil unit 134 is disposed on the lower part of the inner side 120IS of the first coil unit 120.

[0061] The internal upper coil unit 132 and the internal lower coil unit 134 may have shapes symmetrical to each other in a third direction (i.e., the vertical direction). The internal upper coil unit 132 may include a first upper body (hereinafter referred to as "first body") B1U and first upper terminals (hereinafter referred to as "first terminals") PI1U and PI2U. The first body B1U may be disposed on the upper part of the inner side 120IS of the first coil unit 120, and the first terminals PI1U and PI2U may protrude from one upper end US1 of the first body B1U in a first positive direction intersecting the vertical direction.

[0062] The internal upper coil unit 132 may include: a first inner upper terminal PI1U, formed at one end of the internal upper coil unit 132 and extending in a first direction intersecting with a third direction; and a second inner upper terminal PI2U, formed at the other end of the internal upper coil unit 132 and extending in the first direction intersecting with a third direction.

[0063] The internal lower coil unit 134 may include a first lower body (hereinafter referred to as "first body") B1L and first lower terminals (hereinafter referred to as "first terminals") PI1L and PI2L. The first body B1L is disposed in the lower part of the inner side 120IS of the first coil unit 120, and the first terminals PI1L and PI2L protrude from one upper end of the first body B1L in a first positive direction intersecting the vertical direction.

[0064] The internal lower coil unit 134 may include: a first inner lower terminal PI1L, formed at one end of the internal lower coil unit 134 and extending in a first direction; and a second inner lower terminal PI2L, formed at the other end of the internal lower coil unit 134 and extending in a first direction.

[0065] As described above, the first terminals PI1U, PI2U, PI1L, and PI2L can be bent from the inside of the core unit 110 and can protrude outward from the core unit 110.

[0066] Furthermore, the internal coil unit 130 may include guide protrusions G1U and G2U extending in the horizontal direction to overlap with the upper surface of the first coil unit 120 in the vertical direction. Thus, first terminals PI1U, PI2U, PI1L, and PI2L may be formed at one end of the internal coil unit 130, and the guide protrusions G1U and G2U extend in the region between one end and the other end of the internal coil unit 130. That is, the internal upper coil unit 132 and the internal lower coil unit 134 may each also include guide protrusions G1U and G2U.

[0067] For example, as shown, the guide protrusions G1U and G2U can protrude from the other upper end US2 of the first body B1U opposite to the upper end US1 in a negative first direction and are disposed above the first coil unit 120.

[0068] In this embodiment, the guide protrusions G1U and G2U can prevent the first coil unit 120 from deviating from the set position in the vertical direction, that is, the guide protrusions G1U and G2U (and / or G1L and G2L) can guide the first coil unit 120 to remain in the set position.

[0069] The protruding length L1 of the first terminals PI1U, PI2U (or PI1L, PI2L) can be greater than the protruding length L24 of the guide protrusions G1U, G2U (or G1L, G2L).

[0070] Meanwhile, the external coil unit 140 may include an external upper coil unit 142 and an external lower coil unit 144 disposed relative to each other in the vertical direction.

[0071] The outer upper coil unit 142 is disposed on the upper side of at least a portion of the outer side 120OS of the first coil unit 120, and the outer lower coil unit 144 may be disposed on the lower side of at least a portion of the outer side 120OS of the first coil unit 120.

[0072] The outer upper coil unit 142 and the outer lower coil unit 144 may have shapes that are symmetrical to each other in the third direction (i.e., the vertical direction).

[0073] The external upper coil unit 142 may include a second upper body (hereinafter referred to as "second body") B2U and second upper terminals (hereinafter referred to as "second terminals") PO1U and PO2U. The second body B2U may be disposed on at least a portion of the outer side 120OS of the first coil unit 120, and the second terminals PO1U and PO2U may protrude from the second body B2U in a positive first direction.

[0074] The external upper coil unit 142 may include: a first outer upper terminal PO1U, formed at one end of the external upper coil unit 142 and extending in a first direction; and a second outer upper terminal PO2U, formed at the other end of the external upper coil unit 142 and extending in a first direction.

[0075] Similarly, the external lower coil unit 144 may include a second lower body (hereinafter referred to as "second body") B2L and second lower terminals (hereinafter referred to as "second terminals") PO1L and PO2L. The second body B2L may be disposed on at least a portion of the outer side 120OS of the first coil unit 120, and the second terminals PO1L and PO2L may protrude from the second body B2L in a first positive direction.

[0076] The external lower coil unit 144 may include: a first outer lower terminal PO1L, formed at one end of the external lower coil unit 144 and extending in a first direction; and a second outer lower terminal PO2L, formed at the other end of the external lower coil unit 144 and extending in a first direction.

[0077] One end and the other end of each of the internal upper coil unit 132, the internal lower coil unit 134, the external upper coil unit 142, and the external lower coil unit 144 can be formed to extend in the first direction. That is, all the first terminals PI1U, PI2U, PI1L, and PI2L and the second terminals PO1U, PO2U, PO1L, and PO2L can be formed to extend in the first direction.

[0078] Furthermore, when viewed in a second direction perpendicular to the first direction and the third direction, the positions of the first outer upper terminal PO1U, the second outer upper terminal PO2U, the first outer lower terminal PO1L, and the second outer lower terminal PO2L can be set between the first inner upper terminal PI1U and the first inner lower terminal PI1L.

[0079] As described above, the coil unit according to the embodiment may include a plurality of terminals protruding in a first direction.

[0080] For example, when the transformer 100 is running in the sensor tap structure, the second terminals PO1U and PO2U can operate in pairs with the first terminals PI1L and PI2L, and the first terminals PI1U and PI2U can operate in pairs with the second terminals PO1L and PO2L.

[0081] According to the embodiment, the internal upper coil unit 132 and the external lower coil unit 144 can be electrically connected to each other, and the internal lower coil unit 134 and the external upper coil unit 142 can be electrically connected to each other.

[0082] In addition, the outer coil unit 140 may be configured such that 50% or more of its outer surface area is exposed outside the core unit 110.

[0083] In addition, the second bodies B2U and B2L can cover the second to fourth outer sides SS2, SS3 and SS4 of the first coil unit 120, and expose the first outer side SS1.

[0084] At least one of the first coil unit 120 or the second coil units 130 and 140 described above can be replaced with Litz wire or copper plate coil, but the embodiments are not limited thereto.

[0085] According to the embodiment, the internal coil unit 130 and the external coil unit 140 are each plate coils.

[0086] According to an embodiment, the transformer 100 may further include an internal coil frame (or coil holder) IB. The internal coil frame IB is disposed in (or inside) the internal coil unit 130. The internal coil frame IB is used to fix the position of the internal coil unit 130.

[0087] The power supply device 200 according to an embodiment is described schematically below with reference to the accompanying drawings.

[0088] Figure 8a and Figure 8b The figures shown are a plan view and a partial side view of the power supply device 200 according to an embodiment. For ease of understanding, Figure 8b Only transformer 250 and printed circuit board 210 are shown.

[0089] The power supply device 200 according to an embodiment may include a printed circuit board 210, a busbar 230, a rectifier 242, and a transformer 250. Furthermore, the power supply device 200 may also include a fan 220 and an inductor 260. Figure 8a In the diagram, for ease of description, the portion of the busbar 230 that is covered and not visible is shown as a dashed line.

[0090] For example, Figure 8a The printed circuit board 210 and inductor 260 shown can respectively perform the same functions as the first printed circuit board 20 and inductor 200 in the prior art documents. The embodiments do not limit the specific structure of components 210 and 260, so their detailed descriptions are omitted.

[0091] Transformer 250 is mounted on printed circuit board 210. Since transformer 250 is related to the aforementioned reference... Figures 1 to 7b The transformer 100 is the same, so its repeated description is omitted.

[0092] Busbar 230 may be disposed above transformer 250 and inductor 260. Busbar 230 may be electrically connected to transformer 250 and inductor 260. For example, the aforementioned first terminals PI1U, PI2U, PI1L, PI2L and second terminals PO1U, PO2U, PO1L, PO2L may be electrically connected to busbar 230. The terminals may be connected to each other via busbar 230, or connected to an external circuit board or independent electrical components.

[0093] Although not shown, the first wire W1 and the second wire W2 (i.e., conductive wires) can be connected to the first coil unit 120 to supply power to the first coil unit 120.

[0094] A rectifier 242 may be disposed on the side of the transformer 250. The rectifier 242 may be used to rectify the alternating current output from the second coil units 130, 140 of the transformer 250. For example, the rectifier 242 may be a synchronous rectifier, but the embodiments do not limit the rectifier 242 to any specific type.

[0095] Reference Figure 8b The portion of the second body B2 (B2U, B2L) covering the second outer side SS2 can be configured to face the busbar or printed circuit board 210 to achieve electrical connection.

[0096] The transformer according to the comparative example and the transformer according to this embodiment are described below with reference to the accompanying drawings.

[0097] The transformer described in the comparative example may have features corresponding to those in existing technical documents. Figure 4 The transformer shown has a similar structure.

[0098] The transformer according to the comparative example can have the following construction: the primary and secondary coils are alternately stacked vertically inside the core to reduce leakage inductance and improve efficiency. In this case, the connection between the primary and secondary coils is enhanced, thereby improving the efficiency of the components, but heat will concentrate in the stacked secondary coils, thus reducing heat dissipation.

[0099] Furthermore, in the comparative example, the primary coil is placed between the secondary coils, resulting in a complex discontinuous winding structure, which in turn leads to manufacturing difficulties and increased manufacturing costs.

[0100] Figure 9 This is a schematic diagram illustrating the airflow speed when the fan 220 shown in Figure 8 is running.

[0101] In typical power supply units, the busbar 230 is positioned above the transformer 250, and the rectifier 242 is positioned on the side of the transformer 250. Therefore, the airflow path is blocked, preventing it from reaching the transformer, leading to difficulties in heat dissipation.

[0102] like Figure 9 As shown, when the fan 220 is running, a large amount of air can flow between the printed circuit board 210 and the transformer 250. Therefore, according to this embodiment, the second body B2 of the external coil unit 140 disposed on the second outer surface SS2 is configured to face the printed circuit board 210, as shown... Figure 8b As shown, 50% or more of the outer coil unit 140 is exposed outside the core unit 110. In this case, the second body B2 of the outer coil unit 140 is exposed to a large airflow path, and the surface of the second coil unit 140 through which a large current flows is exposed to the air, thereby maximizing the cooling efficiency of the fan 220 and improving heat dissipation characteristics.

[0103] Furthermore, according to this embodiment, the outer coil unit 140 surrounds the first coil unit 120 and maintains the overall shape, eliminating the need for an external coil frame. Therefore, the external coil frame is omitted, thereby reducing the manufacturing cost of the transformer.

[0104] Furthermore, according to this embodiment, since the inner coil unit 130 and the outer coil unit 140 are respectively disposed on the inner side 120IS and the outer side 120OS of the first coil unit 120, the connection between the first coil unit 120 and the second coil units 130 and 140 can be enhanced, thereby reducing the leakage inductance of the transformer 100.

[0105] Furthermore, in this embodiment, the internal coil unit 130 and the external coil unit 140 are configured in a symmetrical shape in the vertical direction. That is, when the first terminals PI1U, PI1L, PI2U, PI2L and the second terminals PO1U, PO2U, PO1L, PO2L are arranged as shown in the figure, each component is driven symmetrically during operation, thereby improving the balance of the components (so that the magnetic flux is not concentrated in one area).

[0106] A power supply device including a transformer according to another embodiment will be described below.

[0107] Figure 10a and Figure 10b These are schematic sectional views and connection sectional views of a power supply device according to another embodiment.

[0108] According to another embodiment, the power supply device may include a transformer 100, an insulating plate (or insulating fixing unit) 400, and a busbar 300. Furthermore, the power supply device may also include a printed circuit board (not shown). Additionally, the power supply device may also include a rectifier (not shown). Furthermore, the power supply device may also include a fan (not shown). Furthermore, the power supply device may also include an inductor (not shown).

[0109] For example, Figure 10a and Figure 10b The printed circuit board, rectifier, fan, and inductor of the power supply device shown can be respectively connected to... Figure 8a The printed circuit board 210, rectifier 242, fan 220 and inductor 260 are arranged in a similar manner.

[0110] The insulating plate 400 may include multiple through holes TH, which are formed to allow multiple terminals P1, P2 of the coil unit to pass through, and may be plate-shaped (or film-shaped).

[0111] The insulating plate 400 may include a first surface S1 facing the coil unit or core unit 110 and a second surface S2 opposite to the first surface S1.

[0112] The insulating plate 400 can be disposed between the core unit 110 and the busbar 300.

[0113] Busbar 300 can be disposed on insulating plate 400. Busbar 300 can be disposed on the second surface S2 of insulating plate 400. Therefore, busbar 300 can be in contact with the second surface S2 of insulating plate 400.

[0114] For example, busbar 300 can be positioned above transformer 100 and inductor, and can be electrically connected to transformer 100 and inductor.

[0115] A rectifier may be disposed on a side surface of transformer 100. The rectifier may be used to rectify the alternating current output via the secondary coil of transformer 100. For example, the rectifier may be a synchronous rectifier, but the embodiment does not limit the specific type of rectifier.

[0116] like Figure 10b As shown, the insulating plate 400 may be spaced apart from the core unit 110 of the transformer 100 in a first direction, and the spacer SP may define a flow path through which fluid (e.g., air) passes. For example, the width W of the flow path SP in the first direction may be greater than 0 and less than or equal to 3.5 mm. However, this embodiment is not limited to this. That is, the insulating plate 400 may be spaced apart from the core unit 110 in the first direction by a distance greater than 0 and less than or equal to 3.5 mm.

[0117] Furthermore, at least a portion of the insulating plate 400 may overlap with the core unit 110 of the transformer 100 in the first direction. That is, the planar area of ​​the insulating plate 400 in the second and third directions may be less than or equal to the planar area of ​​the core unit in the second and third directions.

[0118] Furthermore, the first thickness T1 of the insulating plate 400 in the first direction may be less than the second thickness T2 of the busbar 300 in the first direction. However, the embodiments are not limited to this.

[0119] The following description will refer to the accompanying drawings. Figure 10a and Figure 10b An example of a power supply device is shown.

[0120] Figures 11a to 11d They are respectively Figure 10a and Figure 10b Exploded perspective view, connected perspective view, side view and plan view of an embodiment of the power supply device shown. Figure 11e for Figure 10a The diagram shows the connection of the power supply unit after busbar 300 has been removed.

[0121] Figures 11a to 11e The power supply device shown may include a core unit 110, a coil unit, an insulating plate 400, and a busbar 300. The core unit 110, the coil unit, the insulating plate 400, and the busbar 300 are respectively connected to… Figure 10a and Figure 10b The core unit 110, coil unit, insulating plate 400, and busbar 300 shown are identical. Therefore, identical components are referred to by the same reference numerals, and repeated descriptions are omitted.

[0122] When the transformer 100 of the power supply device according to another embodiment is Figures 1 to 7b When implemented as shown, Figures 11a to 11e The power supply device shown can be constructed as follows. For ease of understanding, it is assumed that... Figure 10a , Figure 10b as well as Figures 11a to 11e The power supply device shown includes Figures 1 to 7b The transformer 100 is shown, and the same reference numerals are used to omit repeated descriptions of the transformer 100. However, the power supply device according to another embodiment may also include a plurality of terminals (e.g., first terminal and second terminal) protruding in the same direction. Figures 1 to 7b The transformer 100 shown is constructed from different transformers.

[0123] The transformer 100 can be mounted on a printed circuit board.

[0124] Figure 10a and Figure 10b The multiple terminals shown may be the first inner upper terminal PI1U, the second inner upper terminal PI2U, the first inner lower terminal PI1L, the second inner lower terminal PI2L, the first outer upper terminal PO1U, the second outer upper terminal PO2U, the first outer lower terminal PO1L, and the second outer lower terminal PO2L.

[0125] Combination Figures 11a to 11e The first inner upper terminal PI1U, the second inner upper terminal PI2U, the first inner lower terminal PI1L, and the second inner lower terminal PI2L can be configured to face each other in the third direction (i.e., the vertical direction), and the first outer upper terminal PO1U, the second outer upper terminal PO2U, the first outer lower terminal PO1L, and the second outer lower terminal PO2L can be configured to face each other in the third direction.

[0126] In this case, the through holes of the insulating plate 400 may include the first to fourth through holes TH1 to TH4.

[0127] The first through hole TH1 includes through holes TH11 (1-1) and TH12 (1-2) through which the first inner upper terminal PI1U and the second inner upper terminal PI2U respectively pass. The second through hole TH2 includes through holes TH21 (2-1) and TH22 (2-2) through which the first inner lower terminal PI1L and the second inner lower terminal PI2L respectively pass. The third through hole TH3 includes through holes TH31 (3-1) and TH32 (3-2) through which the first outer upper terminal PO1U and the second outer upper terminal PO2U respectively pass. The fourth through hole TH4 includes through holes TH41 (4-1) and TH42 (4-2) through which the first outer lower terminal PO1L and the second outer lower terminal PO2L respectively pass.

[0128] In addition, the manifold 300 includes fifth to eighth through holes TH5 to TH8, which correspond to (or are connected to) the first to fourth through holes TH1 to TH4 respectively.

[0129] The first inner upper terminal PI1U and the second inner upper terminal PI2U, passing through the first through hole TH1, can be disposed in the fifth through hole TH5. The first inner lower terminal PI1L and the second inner lower terminal PI2L, passing through the second through hole TH2, can be disposed in the sixth through hole TH6. The first outer upper terminal PO1U and the second outer upper terminal PO2U, passing through the third through hole TH3, can be disposed in the seventh through hole TH7. The first outer lower terminal PO1L and the second outer lower terminal PO2L, passing through the fourth through hole TH4, can be disposed in the eighth through hole TH8.

[0130] Alternatively, according to an embodiment, each of the fifth to eighth through holes TH5 to TH8 may be replaced with a blind hole.

[0131] The first inner upper terminal PI1U, the second inner upper terminal PI2U, the first inner lower terminal PI1L, the second inner lower terminal PI2L, the first outer upper terminal PO1U, the second outer upper terminal PO2U, the first outer lower terminal PO1L, and the second outer lower terminal PI2L respectively disposed in the fifth to eighth through holes TH5 to TH8 can be made of copper (Cu) for example, and can be fixedly connected to the busbar 300 by adhesive or the like.

[0132] Busbar 300 may include a first busbar and a second busbar. The first busbar corresponds to the portion connecting the inner upper coil unit 132 to the outer lower coil unit 144. Similarly, the second busbar corresponds to the portion connecting the inner lower coil unit 134 to the outer upper coil unit 142.

[0133] The spacing between the busbar 300 and the insulating plate 400 can be less than the spacing between the insulating plate 400 and the core unit 110.

[0134] The following description, with reference to the accompanying drawings, describes a power supply device according to a comparative example and a power supply device according to another embodiment.

[0135] In the comparative example, the insulating plate 400 is omitted, and the terminals corresponding to the first inner upper terminal, second inner upper terminal, first inner lower terminal, second inner lower terminal, first outer upper terminal, second outer upper terminal, first outer lower terminal, and second outer lower terminal in the above embodiment are directly fastened to the busbar. In this case, the first inner upper terminal, second inner upper terminal, first inner lower terminal, second inner lower terminal, first outer upper terminal, second outer upper terminal, first outer lower terminal, and second outer lower terminal need to be fixed in precise positions on the busbar. However, the busbar located above the transformer is not supported by a separate support member, but only by structures located below and to the side of the busbar. Therefore, as Figure 11dAs shown, since the busbar 300 is composed of independent pieces 302 to 310 that are individually connected to the first inner upper terminal, the second inner upper terminal, the first inner lower terminal, the second inner lower terminal, the first outer upper terminal, the second outer upper terminal, the first outer lower terminal, and the second outer lower terminal, it is difficult to assemble the busbar in a flat state.

[0136] Furthermore, in the comparative example, the terminals corresponding to the first inner upper terminal, second inner upper terminal, first inner lower terminal, second inner lower terminal, first outer upper terminal, second outer upper terminal, first outer lower terminal, and second outer lower terminal of this embodiment are only fixed to the busbar with adhesive. Therefore, the first inner upper terminal, second inner upper terminal, first inner lower terminal, second inner lower terminal, first outer upper terminal, second outer upper terminal, first outer lower terminal, and second outer lower terminal connected to the busbar may not be accurately held in the expected position, making it difficult to secure the busbar.

[0137] In contrast, according to this embodiment, the insulating plate 400 is disposed between the busbar 300 and the transformer 100, and the first inner upper terminal PI1U, the second inner upper terminal PI2U, the first inner lower terminal PI1L, the second inner lower terminal PI2L, the first outer upper terminal PO1U, the second outer upper terminal PO2U, the first outer lower terminal PO1L, and the second outer lower terminal PO2L of the transformer 100 are initially fixed by the insulating plate 400. Subsequently, the first inner upper terminal PI1U, the second inner upper terminal PI2U, the first inner lower terminal PI1L, the second inner lower terminal PI2L, the first outer upper terminal PO1U, the second outer upper terminal PO2U, the first outer lower terminal PO1L, and the second outer lower terminal PO2L are connected to the busbar 300. Therefore, each independent busbar piece 302 to 310 can be fixed as a whole, and the process defect rate can be reduced.

[0138] Furthermore, according to this embodiment, the insulating plate 400 can support the busbar 300, thereby improving the flatness of the busbar 300 during assembly, and the power supply device can be manufactured without the need for additional fixtures, coil frames or structural components.

[0139] Furthermore, according to this embodiment, a gap space SP is defined between the insulating plate 400 and the transformer 100, and cooling fluid can flow into and out of this gap space. Therefore, the transformer 100 and the busbar 300 can be cooled more quickly.

[0140] Although this disclosure has been specifically shown and described in conjunction with exemplary embodiments, these embodiments are presented for illustrative purposes only and are not intended to limit the disclosure. Those skilled in the art will understand that various changes in form and detail may be made without departing from the essential characteristics of the embodiments described herein. For example, the constructions set forth in the embodiments may be modified and applied. Furthermore, such modifications and applications should be interpreted as falling within the scope of this disclosure as defined by the appended claims.

[0141] [Publicly disclosed implementation methods]

[0142] Various embodiments have been described in detail in the implementation of this disclosure.

[0143] [Industrial Applicability]

[0144] The power supply device including the transformer according to this embodiment can be applied to vehicles or electronic devices (such as household appliances).

Claims

1. A power supply device, comprising: A core unit includes an upper core and a lower core disposed facing the upper core in a first direction; A coil unit, partially housed between the upper core and the lower core, the coil unit including a plurality of terminals projecting in a second direction; An insulating board includes a plurality of through holes, the plurality of through holes being configured to allow a plurality of terminals to pass through the plurality of through holes respectively; as well as Busbars are disposed on the insulating plate.

2. The power supply device according to claim 1, wherein, The insulating plate is disposed between the core unit and the busbar.

3. The power supply device according to claim 1, wherein, The insulating plate is spaced apart from the core unit in the second direction.

4. The power supply device according to claim 3, wherein, The spacing in the second direction is greater than 0 and less than or equal to 3.5 mm.

5. The power supply device according to claim 1, wherein, The busbar contacts the second surface of the insulating plate.

6. The power supply device according to claim 3, wherein, The busbar and the insulating plate are at least partially spaced apart from each other.

7. The power supply device according to claim 6, wherein, The distance between the busbar and the insulating plate is less than the distance between the insulating plate and the core unit.

8. The power supply device according to claim 1, wherein, At least a portion of the insulating plate overlaps with the core unit in the second direction.

9. The power supply device according to claim 1, wherein, The first thickness of the insulating plate in the second direction is less than the second thickness of the busbar in the second direction.

10. The power supply device according to claim 1, wherein, The coil unit includes: A first coil unit is configured to surround the central leg of the core unit; and The second coil unit is disposed on at least a portion of the inner and outer sides of the first coil unit. The second coil unit includes: An internal coil unit is disposed on at least a portion inside the first coil unit; and An external coil unit is disposed on at least a portion outside the first coil unit. The internal coil unit includes: An internal upper coil unit is disposed on the upper part inside the first coil unit; and The outer lower coil unit is disposed on the lower part inside the first coil unit. The external coil unit includes: An external upper coil unit is disposed on the upper side of at least a portion of the outer side of the first coil unit; and An external lower coil unit is disposed on at least a portion of the lower side outside the first coil unit. The internal upper coil unit includes: The first body is disposed on the upper part inside the first coil unit; and The first terminal protrudes from one upper end of the first body in a first direction intersecting the vertical direction. The internal lower coil unit includes: The second body is disposed on the lower part inside the first coil unit; and The second terminal protrudes from a lower end of the second body in the first direction. The external upper coil unit includes: The third body is disposed on the upper side of at least a portion of the outer side of the first coil unit; and The third terminal protrudes from the third body in the first direction. The external lower coil unit includes: The fourth body is disposed on the lower side of at least a portion of the outer side of the first coil unit; and The fourth terminal protrudes from the fourth body in the first direction, and The plurality of terminals include the first terminal to the fourth terminal.

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