transformer

Abstract

A transformer according to an embodiment includes a coil portion including a primary coil and a secondary coil spaced apart from the primary coil, a core portion including an upper core supported on a top surface of the coil portion and a lower core supported on a bottom surface of the coil portion, and a bobbin accommodating both end portions of the coil portion.

Description

Technical Field

[0001] This disclosure relates to a transformer. Background Technology

[0002] Typically, a power supply is required to drive electronic devices, and power supply devices such as power supply units (PSUs) are generally used to supply power to the electronic devices.

[0003] In particular, display devices such as flat-panel TVs need to be thin and are continuously being implemented in increasingly larger sizes. Therefore, it is necessary to reduce the thickness of such large-size displays while meeting their increased power requirements.

[0004] In a power supply unit (PSU), the transformer occupies a relatively large volume compared to other components. To achieve a thin transformer, methods are typically considered to omit thick components from the transformer or to adjust the number of thick components. For example, in recent years, multiple low-capacity thin transformers have been used in the power supply units that constitute flat panel display devices.

[0005] In particular, in high-capacity transformers used in large TVs with a rated power of 500 W or more, the core has increased dimensions compared to a conventional core. This can lead to an imbalance in the thickness of the back side of the core or damage to the core after heat treatment for molding. This can cause heat generation during transformer operation, resulting in a deterioration in transformer efficiency. Furthermore, depending on the shape of the secondary coil, the heat generated in the transformer may increase, and the insulation coating may be damaged. Summary of the Invention

[0006] Technical issues

[0007] The technical objective of this disclosure is to provide a transformer with a reduced thickness and the ability to quickly dissipate heat from the coil to the outside, thereby exhibiting improved heat dissipation characteristics.

[0008] Another technical objective of this disclosure is to provide a display device including the aforementioned transformer.

[0009] The technical tasks of this disclosure are not limited to those described above, and other technical tasks not mentioned herein will be clearly understood by those skilled in the art based on the following description.

[0010] Technical solution

[0011] The transformer according to the embodiment may include: a coil unit including a primary coil and a secondary coil spaced apart from the primary coil; a core unit including an upper core supported on an upper surface of the coil unit and a lower core supported on a lower surface of the coil unit; and a bobbin receiving two opposite ends of the coil unit.

[0012] In the example, the upper core may include a first upper core and a second upper core divided in a first direction, and the lower core may include a first lower core and a second lower core divided in a first direction.

[0013] In the example, the first direction can be parallel to the major axis of the spool.

[0014] In the example, the spool may include a central portion comprising: a hollow portion that accommodates a core unit; a first portion that accommodates one of two opposite ends of a coil unit; and a second portion that accommodates the remaining one of the two opposite ends of the coil unit and is located opposite to the first portion in a first direction, wherein the hollow portion is inserted between the first portion and the second portion; a first terminal portion that is coupled to the first portion and includes a first terminal connected to a secondary coil; a second terminal portion that is coupled to the second portion and includes a second terminal connected to a primary coil and is located opposite to the first terminal portion in the first direction; a first mounting support portion disposed inside the first terminal portion and supporting one end of the secondary coil; and a second mounting support portion disposed inside the second terminal portion and supporting the other end of the secondary coil.

[0015] In the example, the first mounting support may include a first support plate and a second support plate, which are spaced apart from each other in a second direction intersecting the first direction. The secondary coil may include an upper turn and a lower turn. One end of the lower turn of the secondary coil may be disposed between the first support plate and the second support plate, and one end of the upper turn of the secondary coil may be disposed between the second support plate and the first part.

[0016] In the example, the second support plate may also include a guide groove that guides one end of the upper turn of the secondary coil toward the lower turn.

[0017] In the example, each of the first and second mounting supports may further include a guide that defines a space for accommodating the primary coil.

[0018] In the example, the guide portion of the second mounting support can determine the degree of bending at the other end of the secondary coil.

[0019] In the example, the second mounting support may include a third support plate and a fourth support plate spaced apart from each other in a second direction intersecting the first direction, the other end of the lower turn of the secondary coil may be disposed between the third support plate and the fourth support plate, and the other end of the upper turn of the secondary coil may be disposed between the fourth support plate and the second part.

[0020] In the example, in the direction where the upper and lower cores face each other, the thickness of the frame defining the hollow portion in the center can be equal to or less than the distance from the upper surface of the upper core to the bottom surface of the lower core.

[0021] In the example, the first upper core may include a first side surface facing the second upper core in a first direction, the second upper core may include a second side surface opposite to the first side surface in a first direction, the first lower core may include a third side surface facing the second lower core in a first direction, the second lower core may include a fourth side surface opposite to the third side surface in a first direction, the first side surface and the second side surface may be bonded to each other using a first insulating adhesive, and the third side surface and the fourth side surface may be bonded to each other using a second insulating adhesive.

[0022] In the example, the primary coil can have an overall planar shape.

[0023] In the example, each of the first upper core and the second upper core may include: a first outer leg portion, the first outer leg portion protruding in a second direction intersecting the first direction and extending in the first direction; a second outer leg portion, the second outer leg portion being spaced upward from the first outer leg portion at a third point intersecting each of the first and second directions, protruding in the second direction and extending in the first direction; and a first central leg portion, the first central leg portion protruding in the second direction and extending in the first direction between the first outer leg portion and the second outer leg portion, and each of the first lower core and the second lower core may include: a third outer leg portion, the third outer leg portion protruding toward the first outer leg portion in the second direction and extending in the first direction; a fourth outer leg portion, the fourth outer leg portion being spaced upward from the third outer leg portion at a third point, protruding toward the second outer leg portion in the second direction and extending in the first direction; and a second central leg portion, the second central leg portion protruding toward the first central leg portion in the second direction between the third outer leg portion and the fourth outer leg portion and extending in the first direction.

[0024] In the example, the upper surface of the coil unit may be configured to contact the inner surface of each of the first upper core and the second upper core, defined between the first central support and each of the first outer support and the second outer support, and the lower surface of the coil unit may be configured to contact the inner surface of each of the first lower core and the second lower core, defined between the second central support and each of the third and fourth outer supports.

[0025] In the example, the primary coil may include multiple wirings, each wiring including a conductor and a first insulation portion surrounding the conductor, and a second insulation portion having a predetermined winding configuration to surround the multiple wirings and support the core unit.

[0026] According to another embodiment, the display device may include a transformer and a circuit board on which the transformer is disposed.

[0027] The various aspects of this disclosure are only a part of the exemplary embodiments of this disclosure, and those skilled in the art can derive and understand various embodiments reflecting the technical features of this disclosure based on the detailed description of this disclosure described below.

[0028] Beneficial effects

[0029] The advantages of this disclosure are that it can reduce the thickness in the vertical direction, obtain excellent heat dissipation characteristics, improve the manufacturing yield of the core unit, firmly maintain the electrical insulation between the winding of the coil unit and the core unit, and make the total thickness of the transformer uniform.

[0030] The effects achievable through this disclosure are not limited to those described above, and those skilled in the art will clearly understand, based on the following description, other effects not mentioned herein. Attached Figure Description

[0031] Figure 1 This is a top view of the transformer assembled according to an embodiment.

[0032] Figure 2 It is in an inverted state. Figure 1 The diagram shows an assembled perspective view of the transformer.

[0033] Figure 3 yes Figure 1 The diagram shows a plan view of the transformer.

[0034] Figure 4 It is in an inverted state. Figure 3 The transformer shown is a bottom view.

[0035] Figure 5 When viewed from the left Figure 1 The diagram shows a top exploded perspective view of the transformer.

[0036] Figure 6 It is in an inverted state. Figure 5 The transformer shown is an exploded perspective view from below.

[0037] Figure 7 When viewed from the right side Figure 1 The diagram shows a top exploded perspective view of the transformer.

[0038] Figure 8 It is in an inverted state. Figure 7 The transformer shown is an exploded perspective view from below.

[0039] Figure 9 yes Figure 1The transformer shown is a front view.

[0040] Figure 10 yes Figure 1 The rear view of the transformer shown.

[0041] Figure 11 It is a separate core. Figure 1 The transformer shown is a top perspective view.

[0042] Figure 12 It is a separate core. Figure 1 The transformer shown is viewed from below.

[0043] Figure 13 It is a core that has had its top core, bottom core, and center removed. Figure 11 The transformer shown is a top perspective view.

[0044] Figure 14 It is in an inverted state. Figure 13 The transformer shown is viewed from below.

[0045] Figure 15 It further removes the secondary coil. Figure 13 The transformer shown is a top perspective view.

[0046] Figure 16 It further removes the primary coil. Figure 15 The transformer shown is a top perspective view.

[0047] Figure 17 It is in an inverted state. Figure 16 The transformer shown is viewed from below.

[0048] Figure 18 It is the first terminal part of the bobbin that has been removed. Figure 1 The transformer shown is a front view.

[0049] Figure 19 The second terminal portion has been removed. Figure 1 The rear view of the transformer shown.

[0050] Figure 20 This is an exploded perspective view of the second terminal section and the second mounting support section.

[0051] Figure 21 It is in an inverted state. Figure 20 An exploded perspective view of the second terminal section and the second mounting support section shown.

[0052] Figure 22 yes Figure 20 An assembly perspective view of the second terminal section and the second mounting support section shown.

[0053] Figure 23 yes Figure 22 The front view of the second terminal section and the second mounting support section shown.

[0054] Figure 24 This is an exploded perspective view of the first terminal portion and the first mounting support portion.

[0055] Figure 25 It is in an inverted state. Figure 24 An exploded perspective view of the first terminal portion and the first mounting support portion shown.

[0056] Figure 26 yes Figure 24 An assembly perspective view of the first terminal portion and the first mounting support portion shown.

[0057] Figure 27 yes Figure 26 The front view of the first terminal portion and the first mounting support portion shown.

[0058] Figure 28 It is along Figure 3 The sectional view taken by line I-I' in the middle.

[0059] Figure 29 This is a cross-sectional view of the core unit and primary coil according to an embodiment.

[0060] Figure 30 When viewed from the side Figure 1 The diagram shows an assembly perspective view of the transformer's coil unit, the first mounting support, and the second mounting support.

[0061] Figure 31 When viewed from the front Figure 1 The diagram shows an assembly perspective view of the transformer's coil unit, the first mounting support, and the second mounting support. Detailed Implementation

[0062] This disclosure will now be described more fully below with reference to the accompanying drawings, in which various embodiments are illustrated. However, examples may be embodied 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, equivalents, and alternatives falling within the scope and spirit of this disclosure.

[0063] While ordinal numbers including "second," "first," etc., can be used to describe various components, these ordinal numbers are not intended to limit the components. These 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. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0064] It should be understood that when a component is referred to as "connected" or "combined" to another component, the component can be directly connected or combined to the other component, or there may be intermediate components. Conversely, when a component is referred to as "directly connected" or "directly combined" to another component, there are no intermediate components.

[0065] 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" mean that one element is "directly" located on or below the other element, or is configured such that intermediate elements may also be 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 enlarged, omitted, or schematically drawn, and may not accurately reflect actual dimensions.

[0066] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments of this disclosure. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprising” or “having” as used herein specify the presence of the stated features, integers, steps, operations, elements, components, or combinations thereof, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

[0067] Unless otherwise defined, all terms used herein, including technical or scientific terms, shall have the same meaning as commonly understood by one of ordinary skill in the art. Terms (such as those defined in a general dictionary) shall be interpreted as having the same meaning as in the context of the relevant art and shall not be interpreted as having an idealized or overly formal meaning unless expressly defined in the specification.

[0068] In the following description, embodiments will be illustrated with reference to the accompanying drawings. Even when the same or equivalent elements are depicted in different drawings, these elements will be indicated by the same reference numerals, and redundant descriptions will be omitted. Furthermore, the embodiments will be described using a Cartesian coordinate system, but other coordinate systems may also be used. In a Cartesian coordinate system, the x-axis, y-axis, and z-axis shown in each figure are perpendicular to each other, but the embodiments are not limited to this. The x-axis, y-axis, and z-axis may intersect each other obliquely. For ease of description, the x-axis direction is referred to as the "first direction," the z-axis direction as the "second direction," and the y-axis direction as the "third direction." Additionally, the x-axis direction or the y-axis direction may be referred to as a horizontal direction, one of the x-axis direction and the y-axis direction may be referred to as the first horizontal direction, and the other of the x-axis direction and the y-axis direction may be referred to as the second horizontal direction.

[0069] The transformer according to the embodiment will be described in detail below with reference to the accompanying drawings.

[0070] Figure 1 This is a top view of the transformer assembled according to an embodiment. Figure 2 It is in an inverted state. Figure 1 The diagram shows the assembly perspective of the transformer. Figure 3 yes Figure 1 The diagram shown is a plan view of the transformer. Figure 4 It is in an inverted state. Figure 3 The transformer shown is a bottom view. Figure 5 When viewed from the left (i.e., in the +y axis direction) Figure 1 The diagram shows an exploded top view of the transformer. Figure 6 It is in an inverted state. Figure 5 The diagram shows an exploded perspective view of the transformer from below. Figure 7 When viewed from the right (i.e., in the -y-axis direction) Figure 1 The diagram shows an exploded top view of the transformer. Figure 8 It is in an inverted state. Figure 7 The diagram shows an exploded perspective view of the transformer from below. Figure 9 yes Figure 1 The transformer shown is a front view. Figure 10 yes Figure 1 The rear view of the transformer shown is as follows. Figure 11 It is the 110 core that is separated. Figure 1 The diagram shows a top perspective view of the transformer. Figure 12 It is the lower core 120 that is separated. Figure 1 The transformer shown is a bottom perspective view. Figure 13 It is the one that has had its upper core 110, lower core 120, and center part 310 removed. Figure 11 The diagram shows a top perspective view of the transformer. Figure 14It is in an inverted state. Figure 13 The transformer shown is a bottom perspective view. Figure 15 It further removes the secondary coil 220. Figure 13 The diagram shows a top perspective view of the transformer. Figure 16 It further removes the primary coil 210. Figure 15 The diagram shows a top perspective view of the transformer. Figure 17 It is in an inverted state. Figure 16 The transformer shown is a bottom perspective view. Figure 18 The first terminal portion 320 of the spool 300 has been removed. Figure 1 The transformer shown is a front view. Figure 19 The second terminal 330 has been removed. Figure 1 The rear view of the transformer shown is as follows. Figure 20 This is an exploded perspective view of the second terminal portion 330 and the second mounting support portion 350. Figure 21 It is in an inverted state. Figure 20 An exploded perspective view of the second terminal portion 330 and the second mounting support portion 350 shown. Figure 22 yes Figure 20 The image shows an assembled perspective view of the second terminal portion 330 and the second mounting support portion 350. Figure 23 yes Figure 22 The front view of the second terminal portion 330 and the second mounting support portion 350 shown. Figure 24 This is an exploded perspective view of the first terminal portion 320 and the first mounting support portion 340. Figure 25 It is in an inverted state. Figure 24 An exploded perspective view of the first terminal portion 320 and the first mounting support portion 340 shown. Figure 26 yes Figure 24 The assembly perspective view of the first terminal portion 320 and the first mounting support portion 340 shown. Figure 27 yes Figure 26 The front view of the first terminal portion 320 and the first mounting support portion 340 shown, and Figure 28 It is along Figure 3 The sectional view taken by line I-I' in the middle.

[0071] The transformer according to the embodiment may include a core unit 100, a coil unit 200, and a bobbin (unit) 300.

[0072] The core unit 100 can have the characteristics of a magnetic circuit and therefore can be used as a path for magnetic flux. The core unit 100 may include an upper core 110 and a lower core 120. Each of the upper core 110 and the lower core 120 may be divided in a first direction, and the upper core 110 and the lower core 120 may be combined to form a core unit 100.

[0073] The upper core 110 can be divided in a first direction to define a first upper core and a second upper core, and the lower core 120 can be divided in a first direction to define a first lower core and a second lower core.

[0074] Additionally, according to the embodiment, each of the horizontal directions (e.g., the first direction) of the upper core 110 and the lower core 120 that are divided may be parallel to the long axis direction of the spool 300.

[0075] Additionally, refer to Figure 7 The first upper core may include a first side surface S1 facing the second upper core in a first direction, the second upper core may include a second side surface S2 opposite to the first side surface S1 in a first direction, the first lower core may include a third side surface S3 facing the second lower core in a first direction, and the second lower core may include a fourth side surface S4 opposite to the third side surface S3 in a first direction.

[0076] The first side surface S1 and the second side surface S2 can be bonded together using the first insulating adhesive 115, and the third side surface S3 and the fourth side surface S4 can be bonded together using the second insulating adhesive 125.

[0077] The lower core 120 can be positioned to face the upper core 110 in the second direction. In this case, the upper core 110 can be defined as the core located at the position furthest from the upper surface of the circuit board in the second direction, and the lower core 120 can be defined as the core located at the position closest to the upper surface of the circuit board in the second direction. The upper core 110 and the lower core 120 can have shapes that are symmetrical or asymmetrical to each other in the vertical direction (i.e., the z-axis direction). However, for ease of explanation, the following description will be given under the assumption that the upper core 110 and the lower core 120 are symmetrical to each other in the vertical direction.

[0078] Reference Figure 6 Each of the first and second upper cores included in the upper core 110 may include a first outer leg 111, a second outer leg 112, and a first central leg 113.

[0079] The first outer support leg 111 may protrude downward in a second direction from one side of each of the first and second upper cores in a third direction, and may extend in a first direction. The second outer support leg 112 may be spaced apart from the first outer support leg 111 in a third direction, may protrude downward in a second direction, and may extend in a first direction. The first central support leg 113 may be disposed between the first outer support leg 111 and the second outer support leg 112, may protrude downward in a second direction, and may extend in a first direction. The first outer support leg 111, the second outer support leg 112, and the first central support leg 113 may be arranged parallel to each other. Furthermore, the widths of the first outer support leg 111, the second outer support leg 112, and the first central support leg 113 in a third direction may be the same or different from each other.

[0080] On the other hand, the first lower core and the second lower core included in the lower core 120 can face the first upper core and the second upper core respectively, and each of the first lower core and the second lower core can include a third outer support leg 121, a fourth outer support leg 122 and a second central support leg 123.

[0081] The third outer support leg 121 can protrude downward in a second direction from one side of the first and second lower cores in the third direction, and can extend in the first direction. Additionally, the fourth outer support leg 122 can be spaced apart from the third outer support leg 121 in the third direction, can protrude downward in the second direction, and can extend in the first direction. Furthermore, the second central support leg 123 can be disposed between the third outer support leg 121 and the fourth outer support leg 122, can protrude downward in the second direction, and can extend in the first direction. The third outer support leg 121, the fourth outer support leg 122, and the second central support leg 123 can be arranged parallel to each other. Furthermore, the widths of the third outer support leg 121, the fourth outer support leg 122, and the second central support leg 123 in the third direction can be the same or different.

[0082] According to an embodiment, the core unit 100 is supported by the coil unit 200. Therefore, the upper surface of the coil unit 200 (e.g., Figure 5 The 210U shown can be configured to be located on the first inner surface of each of the first upper core and the second upper core, defined between the first central support leg 113 and each of the first outer support leg 111 and the second outer support leg 112. Figure 8 The IS1 and IS2 shown are either in contact or spaced apart. Additionally, the lower surface of the coil unit 200 (e.g., Figure 6 The 210L shown can be configured to be the second inner surface defined between the second central support leg 123 and each of the first and second lower cores and the third outer support leg 121 and the fourth outer support leg 122. Figure 7 IS3 and IS4 shown are either in contact or spaced apart.

[0083] For example, the first central support leg 113 and the second central support leg 123 may have a rectangular shape as shown, or they may have an elliptical planar shape different from that shown, but the embodiments are not limited to any particular shape of the first central support leg 113 and the second central support leg 123.

[0084] Reference Figure 6 The core unit 100 may further include a first space 130 and a second space 140. The first space 130 may be defined by a first outer leg 111, a first central leg 113, a third outer leg 121, and a second central leg 123, and may accommodate a portion of the coil unit 200, described below, namely a portion of the primary coil 210 and a portion of the secondary coil 220. The second space 140 may be defined by a second outer leg 112, a first central leg 113, a fourth outer leg 122, and a second central leg 123, and may accommodate other portions of the primary coil 210 and the secondary coil 220 of the coil unit 200, located in a position opposite to a portion of the primary coil 210 and the secondary coil 220 in the y-axis direction. Therefore, the first space 130 and the second space 140 may be defined to correspond to the thickness and gap between the portions of the coil unit 200 accommodated in the first space 130 and the second space 140. By adjusting the dimensions of the first space 130 and the second space 140, the inductance of the core unit 100 can be controlled. The heating of the transformer can be controlled according to the number of the first space 130 and the second space 140.

[0085] The core unit 100 may contain a magnetic material, such as iron or ferrite, but the embodiments are not limited thereto. In particular, the core unit 100 may be formed of a material having high thermal conductivity.

[0086] According to an embodiment, the upper core 110 can be supported to contact the upper surface of the coil unit 200, and the lower core 120 can be supported to contact the lower surface of the coil unit 200. That is, the spool is not disposed between the upper core 110 and the coil unit 200, nor between the lower core 120 and the coil unit 200. Therefore, the core unit 100 is supported by the coil unit 200.

[0087] On the other hand, the coil unit 200 may include a primary coil 210 and a secondary coil 220.

[0088] like Figures 11 to 14 As shown, a portion of the primary coil 210 may be disposed inside the core unit 100, and another portion of the primary coil 210 may be disposed outside the core unit 100.

[0089] According to an embodiment, the primary coil 210 may have an integral planar shape to support the core unit 100. Therefore, the first upper core and the second upper core 110 may be supported by the upper surface 210U of the primary coil 210, and the first lower core and the second lower core 120 may be supported by the lower surface 210L of the primary coil 210. Additionally, the first upper core and the second upper core 110 are also supported by the secondary coil 220.

[0090] According to an embodiment, the primary coil 210 may have an overall planar shape.

[0091] Figure 29 This is a cross-sectional view of the core units 110 and 120 and the primary coil 210A according to the embodiment. The primary coil 210A corresponds to the primary coil 210 described above in the embodiment.

[0092] The primary coil 210A can have a cross-sectional shape including multiple wirings W. Although in Figure 29 The diagram shows ten wirings W, but the number of wirings W can be greater or less than the number shown.

[0093] According to an embodiment, the primary coil 210A may include multiple wirings W and a second insulation portion 230. Figure 29 Each of the multiple wirings W shown may include a conductor 212 and a first insulation portion 214.

[0094] Conductor 212 is conductive. Therefore, conductor 212 may contain a conductive material, such as copper. That is, conductor 212 corresponds to the core wire of wiring W. As shown, conductor 212 may have a circular cross-sectional shape with a radius R, but the embodiments are not limited to any particular cross-sectional shape of conductor 212.

[0095] The first insulating portion 214 may be an insulating covering surrounding the conductor 212. For example, such as Figure 29 As shown, the first insulating portion 214 may be a double insulating layer comprising a first insulating coating 214-1 and a second insulating coating 214-2 stacked in multiple layers (e.g., two layers). The second insulating coating 214-2 may be configured to contact the conductor 212, and the first insulating coating 214-1 may be disposed on the outermost side of the wiring W.

[0096] The second insulation portion 230 can be formed with a predetermined winding shape to surround multiple wirings W and support the core unit 100. Therefore, the upper core 110 can be supported by the upper surface 210U of the primary coil 210A, and the lower core 120 can be supported by the lower surface 210L of the primary coil 210A.

[0097] The second insulating portion 230 may include an adhesive and an insulating material. For example, the second insulating portion 230 may be formed of a polymer resin such as polyvinyl-based resin, polyethylene-based resin, fluoropolymer resin, silicone resin, or nylon. Therefore, multiple wirings W can be bonded to each other through the second insulating portion 230.

[0098] Additionally, the secondary coil 220 may be spaced apart from the primary coil 210 and extend along the outer periphery of the primary coil 210 in the winding direction of the primary coil 210, and at least a portion of the secondary coil 220 may be housed together with the primary coil 120 in the first space 130 and the second space 140. The secondary coil 220 may be wound such that at least one secondary winding is arranged in a single layer or multiple layers. For example, as shown, the secondary coil 220 may be formed such that a wire is wound with multiple turns (e.g., two or three turns) to be arranged in multiple layers. In the following, in a secondary coil 220 with a wire wound with two turns, the upper winding is referred to as the "upper turn" or "upper coil," and the winding located below the upper turn is referred to as the "lower turn" or "lower coil."

[0099] Additionally, according to an embodiment, in order to achieve a center-tap structure, the secondary winding 220 can have a totem-pole structure. For example... Figure 5 As shown, when three wires form a winding, one end of the secondary coil 220 may include four windings WS1, WS2, WS3, and WS4. In this case, the totem pole structure refers to a structure where, when the first winding WS1 is connected to the negative (-) terminal of the power supply and the fourth winding WS4 is connected to the positive (+) terminal of the power supply, each of the second winding WS2 and the third winding WS3 is grounded, and the second winding WS2 and the third winding WS3 are bonded together on a substrate (not shown). Therefore, the current flowing through the two windings is the same, thus improving efficiency.

[0100] In particular, according to the embodiments, such as Figure 11 and Figure 12 As shown, the secondary coil 220 is also used to support the core unit 100 together with the primary coil 210.

[0101] On the other hand, the spool 300 is used to accommodate two opposite ends of the coil unit 200. According to an embodiment, the spool 300 may include a center portion 310, a first terminal portion 320, a second terminal portion 330, a first mounting support portion 340, and a second mounting support portion 350.

[0102] The spool 300 can be coupled to the core unit 100 and the coil unit 200. In addition, at least a portion of each of the primary coil 210 and the secondary coil 220 can be disposed on the spool 300.

[0103] First, refer to Figure 5 The central portion 310 may include a first portion (or first end) P1 disposed on one side of the central portion 310, a second portion (or second end) P2 disposed on the opposite side of the central portion 310 in the first direction, and a hollow portion 310H (or through hole) formed between the first portion P1 and the second portion P2 to accommodate the core unit 100.

[0104] In the central portion 310, the first portion P1 and the second portion P2 do not overlap with the core unit 100 in a second direction that is vertical. Specifically, the first portion P1 and the second portion P2 extend from the hollow portion 310H in a positive first direction and a negative first direction, respectively. Therefore, the first portion P1 and the second portion P2 are defined as regions that are opposite to each other in the first direction, with the hollow portion 310H inserted therebetween.

[0105] Reference Figure 3 and Figure 4 The first part P1 is a portion that accommodates one of the two opposite ends of the coil unit 200, and the second part P2 is a portion that accommodates the other of the two opposite ends of the coil unit 200.

[0106] The first terminal portion 320 can be coupled to the first part P1 of the central portion 310, and can include a terminal (or pin) (hereinafter referred to as the "first terminal") T1 connected to the secondary coil 220.

[0107] The second terminal portion 330 can be coupled to the second part P2 of the center portion 310, and can include a terminal (hereinafter referred to as "second terminal") T2 connected to the primary coil 210. The first terminal portion 320 and the second terminal portion 330 are located opposite to each other in a first direction.

[0108] For example, as described above, when one end of the secondary coil 220 includes four windings WS1, WS2, WS3, and WS4, the first terminal T1 may include four terminals T11, T12, T13, and T14. However, the embodiment is not limited to any particular number or shape of terminals included in the first terminal T1. In this case, the second terminal T2 may include two terminals T21 and T22. However, the embodiment is not limited to any particular number or shape of terminals included in the second terminal T2.

[0109] Each of the first terminal portion 320 and the second terminal portion 330 can be coupled to the central portion 310 in various ways.

[0110] In the example, refer to Figure 24 and Figure 25 The first terminal portion 320 may include a first-1 groove H11, a first-2 groove H12, a first-3 groove H13, and a first-4 groove H14, and as follows Figure 5 As shown, the central portion 310 may include a first-1 joining portion 310P1 and a first-2 joining portion 310P2. For example... Figure 5 As shown, each of the first-1 joint portion 310P1 and the first-2 joint portion 310P2 may have a stepped structure and may include a protrusion 310PT formed on the stepped surface. In this case, the stepped portions of the first-1 joint portion 310P1 and the first-2 joint portion 310P2 may have a shape suitable for sliding into the first-3 groove H13 and the first-4 groove H14 respectively in a first direction. When the stepped portions of the first-1 joint portion 310P1 and the first-2 joint portion 310P2 are inserted into the first-3 groove H13 and the first-4 groove H14 respectively, the protrusion 310PT of the first-1 joint portion 310P1 and the first-2 joint portion 310P2 can be fitted into the first-1 groove H11 and the first-2 groove H12, so that the first terminal portion 320 can be coupled to the center portion 310.

[0111] Alternatively, the second terminal portion 330 can also be attached to the center portion 310 in the same manner as the first terminal portion 320 is attached to the center portion 310. That is, referring to... Figure 20 and Figure 21 The second terminal portion 330 may include a second-1 groove H21, a second-2 groove H22, a second-3 groove H23, and a second-4 groove H24, and as follows Figure 5 As shown, the central portion 310 may include a first-third joint portion 310P3 and a first-fourth joint portion 310P4. (The last sentence appears to be incomplete and possibly contains errors.) Figure 5 The first-1 joint 310P1 and the first-2 joint 310P2 shown are identical. Each of the first-3 joint 310P3 and the first-4 joint 310P4 may have a stepped structure and may include a protrusion 310PT formed on the stepped surface. In this case, the stepped portions of the first-3 joint 310P3 and the first-4 joint 310P4 may have a shape suitable for sliding into the second-3 groove H23 and the second-4 groove H24 respectively in the first direction. When the stepped portions of the first-3 joint portion 310P3 and the first-4 joint portion 310P4 are inserted into the second-3 groove H23 and the second-4 groove H24 respectively, the protrusions 310PT of the first-3 joint portion 310P3 and the first-4 joint portion 310P4 can be fitted into the second-1 groove H21 and the second-2 groove H22, so that the second terminal portion 330 can be joined to the center portion 310.

[0112] The above-described connection methods are merely examples, and the embodiments are not limited to any particular connection method between each of the first terminal portion 320 and the second terminal portion 330 and the central portion 310.

[0113] Additionally, refer to Figure 3 and Figure 4 The first terminal portion 320 may further include a first inner guide portion 324, and the second terminal portion 330 may further include a second inner guide portion 334. The first inner guide portion 324 separates the upper and lower turns at one end of the secondary coil 220, and the second inner guide portion 334 separates the upper and lower turns at the other end of the secondary coil 220, thereby guiding the secondary coil 220 to maintain a multilayer structure. For this purpose, each of the first inner guide portion 324 and the second inner guide portion 334 may have a shape that protrudes toward the secondary coil 220. In some cases, the first inner guide portion 324 and the second inner guide portion 334 may be omitted.

[0114] Additionally, refer to Figure 9 The first terminal portion 320 may further include a third-1 groove H31, a third-2 groove H32, a third-3 groove H33, and a third-4 groove H34. The third-1 groove H31, the third-2 groove H32, the third-3 groove H33, and the third-4 groove H34 are the portions through which the first winding WS1, the second winding WS2, the third winding WS3, and the fourth winding WS4 are exposed to the outside for welding. That is, the first winding WS1, the second winding WS2, the third winding WS3, and the fourth winding WS4 can be separated from each other by the third-1 groove H31, the third-2 groove H32, the third-3 groove H33, and the third-4 groove H34, so that they are respectively exposed to the outside.

[0115] Reference Figure 10 The second terminal portion 330 may further include a fourth-1 groove H41, a fourth-2 groove H42, a fourth-3 groove H43, and a fourth-4 groove H44. At least a portion of the fourth-1 groove H41, the fourth-2 groove H42, the fourth-3 groove H43, and the fourth-4 groove H44 is the portion through which the primary coil 210 is exposed to the outside for soldering. That is, the primary coil 210 may be separated by at least one of the fourth-1 groove H41, the fourth-2 groove H42, the fourth-3 groove H43, and the fourth-4 groove H44 in order to expose it to the outside.

[0116] In some cases, grooves 3-1 H31 to 4-4 H44 can be omitted.

[0117] On the other hand, the first mounting support portion 340 is disposed inside the first terminal portion 320 and is used to support one end of the secondary coil 220, and the second mounting support portion 350 is disposed inside the second terminal portion 330 and is used to support the other end of the secondary coil 220.

[0118] According to the embodiments, refer to Figures 24 to 27 The first mounting support 340 may include a first support plate 342 and a second support plate 344 spaced apart from each other in a second direction.

[0119] One end of the lower turn of the secondary coil 220 is disposed between the first support plate 342 and the second support plate 344, and one end of the upper turn of the secondary coil 220 is disposed between the second support plate 344 and the first portion P1 of the center portion 310. For this purpose, refer to... Figure 18 The first support plate 342 and the second support plate 344 define a first receiving space SP11, one end of the lower turn is received in the first receiving space SP11, and the second support plate 344 and the first part P1 of the center portion 310 define a second receiving space SP12, one end of the upper turn is received in the second receiving space SP12.

[0120] The first mounting support portion 340 may include a first support plate 342 and a second support plate 344 that are stepped in the vertical direction on the inner side facing the center portion 310. The lower coil may be disposed on the first support plate 342 and the upper coil may be disposed on the second support plate 344.

[0121] According to the embodiments, refer to Figures 20 to 23 The second mounting support 350 may include a third support plate 352 and a fourth support plate 354 spaced apart from each other in the second direction.

[0122] The other end of the lower turn of the secondary coil 220 is disposed between the third support plate 352 and the fourth support plate 354, and the other end of the upper turn of the secondary coil 220 is disposed between the fourth support plate 354 and the second portion P2 of the center portion 310. For this purpose, refer to... Figure 19 The third support plate 352 and the fourth support plate 354 define a third receiving space SP21, one end of the lower turn is received in the third receiving space SP21, and the fourth support plate 354 and the second part P2 of the center portion 310 define a fourth receiving space SP22, the other end of the upper turn is received in the fourth receiving space SP22.

[0123] Figure 30 When viewed from the side Figure 1 The diagram shows an assembled perspective view of the transformer's coil unit 200, the first mounting support 340, and the second mounting support 350. Figure 31When viewed from the front Figure 1 The diagram shows an assembly perspective view of the transformer coil unit 200, the first mounting support 340, and the second mounting support 350.

[0124] The second support plate 344 may also include a guide groove 346H. (See reference...) Figure 30 and Figure 31 The guide groove 346H is used to guide one end of the upper turn of the secondary coil 220 toward the lower turn. Therefore, the upper turn can be bent at the guide groove 346H to become the lower turn.

[0125] In addition, the first mounting support 340 and the second mounting support 350 may also include guides 346 and 356, respectively.

[0126] Reference Figure 16 Guide portions 346 and 356 define the space in which the primary coil 210 is disposed. Therefore, the outermost edge of the primary coil 210 is configured to contact the guide portions 346 and 356. Furthermore, the guide portion 356 of the second mounting support 350 defines the degree of curvature of the other end of the secondary coil 220. That is, since the other end of the secondary coil 220 turns at the guide portion 356, the degree of curvature during the turning can be determined by the radius of curvature of the guide portion 356 of the second mounting support 358.

[0127] According to an embodiment, each of the first mounting support portion 340 and the second mounting support portion 350 can be coupled to the central portion 310. The first mounting support portion 340 can be coupled to the first terminal portion 320, and the second mounting support portion 350 can be coupled to the second terminal portion 330. The coupling of these components will be described below with reference to the accompanying drawings. However, the embodiment is not limited to any particular coupling method.

[0128] Each of the first mounting support 340 and the second mounting support 350 can be combined with the central part 310 in the following manner.

[0129] The first mounting support portion 340 may include at least one of a first-1 protrusion PT11 or a first-2 protrusion PT12, and the central portion 310 may include at least one of a first-1 through hole TH11 or a first-2 through hole TH12. The first-1 protrusion PT11 can be inserted into the first-1 through hole TH11, and the first-2 protrusion PT12 can be inserted into the first-2 through hole TH12, so that the central portion 310 and the first mounting support portion 340 can be coupled to each other.

[0130] The second mounting support portion 350 may include at least one of a second-first protrusion PT21 or a second-second protrusion PT22, and the central portion 310 may include at least one of a second-first through hole TH21 or a second-second through hole TH22. The second-first protrusion PT21 may be inserted into the second-first through hole TH21, and the second-second protrusion PT22 may be inserted into the second-second through hole TH22, such that the central portion 310 and the second mounting support portion 350 can be coupled to each other.

[0131] Reference Figures 24 to 27 The first mounting support portion 340 and the first terminal portion 320 can be combined with each other in the following manner.

[0132] The first terminal portion 320 may further include a first-5 groove H15 and a first-6 groove H16. In the first terminal portion 320, the first-5 groove H15 is located further inward than the first-3 groove H13, and the first-6 groove H16 is located further inward than the first-4 groove H14. In this case, the first wing 344E1 and the second wing 344E2 located at the outermost edge of the end of the second support plate 344 in the second direction have shapes that can slide into the first-5 groove H15 and the first-6 groove H16, respectively. That is, when the first mounting support portion 340 is pushed toward the first terminal portion 320 in the first direction, the first wing 344E1 can slide into the first-5 groove H15, and the second wing 344E2 can slide into the first-6 groove H16, so that the first mounting support portion 340 and the first terminal portion 320 can be engaged with each other.

[0133] Reference Figures 20 to 23 The second mounting support 350 and the second terminal 330 can be combined with each other in the following manner.

[0134] The second terminal portion 330 may include a second-5 groove H25 and a second-6 groove H26. In the second terminal portion 330, the second-5 groove H25 is located further inward than the second-3 groove H23, and the second-6 groove H26 is located further inward than the second-4 groove H24. In this case, the third wing 354E1 and the fourth wing 354E2 located at the outermost edge in the second direction at the end of the fourth support plate 354 have shapes that can slide into the second-5 groove H25 and the second-6 groove H26, respectively. That is, when the second mounting support portion 350 is pushed toward the second terminal portion 330 in the first direction, the third wing 354E1 can slide into the second-5 groove H25, and the fourth wing 354E2 can slide into the second-6 groove H26, so that the second mounting support portion 350 and the second terminal portion 330 can be engaged with each other.

[0135] In the following description, the transformer according to the comparative example and the transformer according to the embodiment will be described with reference to the accompanying drawings.

[0136] In the transformer according to the comparative example, a separate bobbin is also provided between the core unit and the coil unit. In this case, the total thickness of the transformer in the vertical direction increases due to the separate bobbin.

[0137] Conversely, in the transformer according to the embodiment, there is no separate bobbin between the core unit 100 and the coil unit 200. Therefore, the thickness of the transformer in the second direction is determined by the thickness of the core unit 100, and the thickness of the transformer in the vertical direction can be less than the thickness of the transformer in the vertical direction according to the comparative example. For example, refer to... Figure 28 In the second direction where the upper core 110 and the lower core 120 face each other, the thickness TK1 of the frame 319 defining the hollow portion 310H in the center portion 310 can be equal to or less than the distance TK2 from the upper surface 110H of the upper core 110 to the bottom surface 120L of the lower core 120. For example, the total thickness TK2 of the transformer according to the embodiment can be as high as 7.2 mm.

[0138] Furthermore, in this embodiment, since no spool is provided between the coil unit 200 and the core unit 100, excellent heat dissipation characteristics can be obtained. Because the core unit 100 and the coil unit 200 are in contact with each other, the heat generated from the coil unit 200 can be quickly dissipated to the outside through the core unit 100. That is, according to this embodiment, the core unit 100 is used as a heat sink, thus improving heat dissipation characteristics.

[0139] Furthermore, according to the embodiment, due to the first support plate 342 and the second support plate 344 of the first mounting support portion 340, the third support plate 352 and the fourth support plate 354 of the second mounting support portion 350, as well as the first inner guide portion 324 and the second inner guide portion 334, the secondary coil 220 can maintain a double-layer structure including the upper and lower turns, thereby exhibiting further improved heat dissipation characteristics.

[0140] Furthermore, in the transformer according to the comparative example, each of the upper and lower cores is formed as a single body and is not divided in the first direction. Typically, because each of the upper and lower cores is very thin, in the comparative example, the upper and lower cores may be easily damaged during the molding process used to manufacture the cores.

[0141] Conversely, in the transformer according to the embodiment, each of the upper core 110 and the lower core 120 is divided into multiple pieces (e.g., two pieces) in a first direction. When each of the upper core 110 and the lower core 120 is divided in this manner, the problem of easy damage to the upper core 110 and the lower core 120 during manufacturing can be prevented. Therefore, in the embodiment, the manufacturing yield of the core unit 100 is increased.

[0142] Furthermore, when each of the upper core 110 and lower core 120 is sliced ​​into pieces along the minor axis of the spool 300, the pieces may have increased length and therefore be prone to damage. However, in this embodiment, each of the upper core 110 and lower core 120 is sliced ​​along the major axis of the spool 300 rather than along the minor axis, thus reducing the length of each of the first and second upper cores 110 and each of the first and second lower cores 120, thereby preventing the problem of easy core damage.

[0143] Furthermore, in this embodiment, the first side surface S1 of the first upper core and the second side surface S2 of the second upper core are bonded together using a first insulating adhesive 115 with electrical insulating properties, and the third side surface S3 of the first lower core and the fourth side surface S4 of the second lower core are bonded together using a second insulating adhesive 125 with electrical insulating properties. Therefore, electrical insulation between the windings of the coil unit 200 and the core unit 100 can be reliably maintained.

[0144] Furthermore, when welding the first terminal T1 and the second terminal T2, it is necessary to maintain the horizontality of the interlocking components 310, 320, 330, 340, and 350 in the spool 300. This is because maintaining horizontality ensures that the total thickness of the transformer in the vertical direction remains uniform. Therefore, according to the embodiment, the first terminal portion 320 and the first mounting support portion 340 are slidably connected to each other, and the second terminal portion 330 and the second mounting support portion 350 are also slidably connected to each other. Thus, the horizontality of the spool 300 can be maintained, and therefore the total thickness of the transformer can become uniform.

[0145] On the other hand, since the transformer according to the above embodiment is implemented with a thin structure, a circuit board on which such a transformer is disposed can be applied to a display device, such as an ultra-thin OLED TV. Therefore, when the transformer according to the embodiment is mounted on the circuit board of a display device, it can contribute to the thinning of the display device.

[0146] In particular, because the embodiments have excellent heat dissipation characteristics, the heat generation problem caused by the increased power consumption of the display device can be solved.

[0147] While this disclosure has been specifically shown and described with reference to exemplary embodiments thereof, these embodiments are provided for illustrative purposes only and are not intended to limit the disclosure. It will be apparent to those skilled in the art that various changes in form and detail may be made without departing from the essential characteristics of the embodiments set forth herein. For example, the various configurations set forth in the embodiments may be modified and applied. Furthermore, such modifications and applications should be construed as falling within the scope of this disclosure as defined by the appended claims.

[0148] Publication method

[0149] Various embodiments have been described in the manner best suited for carrying out this disclosure.

[0150] Industrial applicability

[0151] The transformer and display device including the transformer according to the embodiment can be applied to display devices such as ultra-thin OLED TVs.

Claims

1. A transformer, comprising: A bobbin unit having a through hole; A core unit is disposed in the through hole of the bobbin unit, and the core unit includes a lower core and an upper core disposed on the lower core; as well as A coil unit is disposed between the lower core and the upper core.

2. The transformer according to claim 1, wherein, The upper core includes a first upper core and a second upper core that are divided in the horizontal direction, and The lower core includes a first lower core and a second lower core that are divided in the horizontal direction.

3. The transformer according to claim 2, wherein, The horizontal direction includes a first horizontal direction and a second horizontal direction that are perpendicular to each other. Each of the upper core and the lower core is divided in the first horizontal direction. The width of the spool unit in the second horizontal direction is greater than the width of the core unit in the second horizontal direction, and The horizontal direction is parallel to the major axis of the spool.

4. The transformer according to claim 1, wherein, The coil unit includes a primary coil and a secondary coil, and The bobbin unit includes a central portion having the through hole, a plurality of mounting support portions disposed at opposite ends of the central portion, and a plurality of terminal portions disposed on the outside of the plurality of mounting support portions.

5. The transformer according to claim 4, wherein, The plurality of mounting supports include a first mounting support surrounding and supporting one end of the secondary coil and a second mounting support surrounding the other end of the secondary coil. The secondary coil includes an upper coil and a lower coil. The first mounting support includes a first support plate and a second support plate that are stepped in the vertical direction on the inner side of the first mounting support facing the center portion. The lower coil is mounted on the first support plate, and The upper coil is mounted on the second support plate.

6. The transformer according to claim 6, wherein, The second support plate also includes a guide groove that guides one end of the upper coil of the secondary coil toward the lower coil.

7. The transformer according to claim 6, wherein, Each of the first mounting support and the second mounting support further includes a guide portion that defines a space for accommodating the primary coil.

8. The transformer according to claim 7, wherein, The guide portion of the second mounting support determines the degree of bending at the other end of the secondary coil.

9. The transformer according to claim 5, wherein, The second mounting support includes a third support plate and a fourth support plate spaced apart from each other in a second direction intersecting the first direction. The other end of the lower coil of the secondary coil is disposed between the third support plate and the fourth support plate, and The other end of the upper coil of the secondary coil is disposed between the fourth support plate and the second part.

10. The transformer according to claim 4, wherein, In the direction in which the upper core and the lower core face each other, the thickness of the frame defining the through hole in the central portion is equal to or less than the distance from the upper surface of the upper core to the bottom surface of the lower core.

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