Transformer module

Abstract

The utility model provides a transformer module which comprises a primary side assembly, a secondary side assembly and a magnetic element. The primary side assembly is provided with a first cover body, a first column body and a first coil. The first column body is connected to the first cover body. The first coil is wound on the first cylinder. The secondary side assembly is provided with a second cover body, a second column body and a second coil. The second column body is connected to the second cover body. The second coil is wound on the second cylinder. The magnetic element is arranged between the primary side assembly and the secondary side assembly. The first column body is fixedly connected to the second column body, and the size of the first column body is larger than that of the second column body.

Description

Technical Field

[0001] This utility model relates to a transformer module, and more particularly to a transformer module that can reduce power loss. Background Technology

[0002] In power systems or electronic equipment, transformers are common power transmission devices used to convert input voltage into different output voltages to meet the needs of various electronic devices. Traditional transformers typically consist of a primary winding and a secondary winding wound on an iron core, converting voltage through the principle of electromagnetic induction.

[0003] However, with the increasing demand for miniaturization and multifunctionality in electronic devices, the structural design and performance optimization of transformers have become particularly important. For example, to improve efficiency and reduce energy loss, transformers can incorporate multi-layer winding designs, use low-loss materials, or incorporate structures for enhanced heat dissipation. However, existing technologies still have room for improvement in terms of conversion efficiency and heat dissipation.

[0004] Therefore, how to design a transformer module that increases conversion efficiency and heat dissipation is a topic worthy of discussion and solution. Utility Model Content

[0005] In view of the shortcomings of the existing technology, this utility model proposes a transformer module to solve the above problems.

[0006] This utility model provides a transformer module, including a primary side assembly, a secondary side assembly, and a magnetic element. The primary side assembly has a first cover, a first column, and a first coil. The first column is connected to the first cover. The first coil is wound around the first column. The secondary side assembly has a second cover, a second column, and a second coil. The second column is connected to the second cover. The second coil is wound around the second column. The magnetic element is disposed between the primary side assembly and the secondary side assembly. The first column is fixedly connected to the second column, and the size of the first column is larger than the size of the second column.

[0007] According to some embodiments of the present invention, the cross-section of the first column forms a first circle, the cross-section of the second column forms a second circle, and the diameter of the first circle is 1.1 to 2 times the diameter of the second circle.

[0008] According to some embodiments of the present invention, the winding frame is made of non-conductive and non-magnetic material.

[0009] According to some embodiments of the present invention, the winding frame further includes an intermediate receiving portion connected between the first sleeve and the second sleeve, and the intermediate receiving portion is configured to receive magnetic elements.

[0010] According to some embodiments of the present invention, the magnetic element is sleeved on the first column, and the magnetic element has a ring structure or a horseshoe structure.

[0011] According to some embodiments of the present invention, the intermediate receiving portion has an intermediate receiving space, the magnetic element is disposed in the intermediate receiving space, and the intermediate receiving portion further has at least one positioning protrusion protruding toward the magnetic element and configured to contact and position the magnetic element.

[0012] According to some embodiments of the present invention, the first cover and the first column are integrally formed, and the first column extends along a first axial direction, wherein the transformer module further includes a ring element disposed on the first cover and covering the first column.

[0013] According to some embodiments of the present invention, when viewed along a second axial direction, the collar element has an arcuate structure, is concave towards the first column, and the second axial direction is perpendicular to the first axial direction, wherein the collar element is made of ferrite, magnetic disk, magnetic conductive tape, or a combination thereof.

[0014] According to some embodiments of the present invention, the first column extends along a first axial direction, and the height of the first coil in the first axial direction is greater than the height of the second coil in the first axial direction.

[0015] According to some embodiments of the present invention, the transformer module further includes a winding frame configured to connect to the primary side assembly and the secondary side assembly. The winding frame has a first sleeve and a second sleeve, which respectively accommodate the first column and the second column, and the first sleeve communicates with the second sleeve.

[0016] This utility model provides a transformer module, including a primary side assembly, a secondary side assembly, and a magnetic element. The first coil of the primary side assembly is sleeved on a first column, and the second coil of the secondary side assembly is sleeved on a second column. The magnetic element is sleeved on either the first or second column. The first column is fixedly connected to the second column, and the diameter of the first column is 1.1 to 2 times the diameter of the second column.

[0017] Based on this configuration, compared with existing transformer modules, the transformer module of this utility model can reduce power loss by more than 16%. Furthermore, since the size of the first column is larger than that of the second column, the leakage inductance of the transformer module and the magnetic lines of force of the first coil can be evenly arranged in the first column, thereby reducing the overall temperature and achieving a good heat dissipation effect.

[0018] Furthermore, the transformer module may further include a ring element disposed on the first cover and surrounding the first column. The ring element is located at the junction of the first column and the first cover and has an arc-shaped structure, concave towards the inward of the first column. Based on this ring element configuration, magnetic lines of force can be prevented from concentrating at the junction of the first column and the first cover, thereby further improving overall heat dissipation efficiency. Attached Figure Description

[0019] This invention will become clear from the following detailed description and accompanying drawings. It should be emphasized that, in accordance with industry standard practice, the various features are not drawn to scale and are for illustrative purposes only. In fact, for clarity, the dimensions of the various features may be arbitrarily enlarged or reduced.

[0020] Figure 1 This is a perspective view of a transformer module according to an embodiment of the present invention;

[0021] Figure 2 This is an exploded perspective view of a transformer module according to an embodiment of the present invention.

[0022] Figure 3 According to an embodiment of the present invention, the transformer module is along... Figure 1 Three-dimensional cross-sectional view of the midline segment AA;

[0023] Figure 4 According to an embodiment of the present invention, the transformer module is along... Figure 1 Cross-sectional view of the midline segment BB;

[0024] Figure 5 This is a top cross-sectional view of a transformer module according to another embodiment of the present invention;

[0025] Figure 6 This is a front view schematic diagram of a transformer module according to an embodiment of the present invention;

[0026] Figure 7 This is a schematic diagram of the magnetic field distribution of the existing transformer module 10;

[0027] Figure 8 This is a schematic diagram of the magnetic field distribution of the transformer module according to this utility model;

[0028] The attached diagram is described as follows:

[0029] 10: Existing transformer modules

[0030] 11: Primary lateral column

[0031] 13: Secondary lateral prism

[0032] 15: Primary coil

[0033] 18: Auxiliary coil

[0034] 100: Transformer Module

[0035] 110: Primary side component

[0036] 112: First cover

[0037] 113: Border

[0038] 114: First column

[0039] 116: First coil

[0040] 118: Auxiliary coil

[0041] 130: Secondary side component

[0042] 132: Second cover

[0043] 134: Second Column

[0044] 136: Second coil

[0045] 150: Magnetic components

[0046] 170: Winding stand

[0047] 171: First Sleeve

[0048] 172: Second Sleeve

[0049] 173: Intermediate Reception Section

[0050] 1731: Intermediate Accommodation Space

[0051] 1733: Positioning convex part

[0052] 180: Collar element

[0053] AX 1: First axial direction

[0054] AX 2: Second Axis

[0055] DT 1: Diameter

[0056] DT 2: Diameter

[0057] HT 1: Height

[0058] HT 2: Height

[0059] LR: Arrow

[0060] TX: Arrow

[0061] X: X-axis

[0062] Y: Y-axis

[0063] Z: Z-axis. Detailed Implementation

[0064] The following discloses many different embodiments or examples to implement different features of the provided object. Specific examples of elements and their arrangements are described below to illustrate the present invention. Of course, these embodiments are merely illustrative and should not be construed as limiting the scope of the present invention. For example, the specification mentions that a first feature is formed on a second feature. This may include embodiments where the first and second feature are in direct contact, or embodiments where there are other features between the first and second feature; in other words, the first and second feature are not in direct contact.

[0065] Furthermore, repeated reference numerals or designations may be used in different embodiments. These repetitions are merely for the purpose of clearly and simply describing the present invention and do not represent a specific relationship between the different embodiments and / or structures discussed. Additionally, the formation, connection, and / or coupling to another feature component in the present invention may include embodiments in which the feature components are formed in direct contact, and may also include embodiments in which additional feature components may be formed to insert into the aforementioned feature component, such that the aforementioned feature components may not be in direct contact. Furthermore, spatially related terms may be used, such as “vertical,” “above,” “up,” “below,” “bottom,” and similar terms (e.g., “downward,” “upward,” etc.). These spatially related terms are intended to cover different orientations of the device including the feature in order to facilitate the description of the relationship between one or more elements or features in the illustrations and another element or feature(s).

[0066] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It is understood that these terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the relevant art and the background or context of this utility model, and should not be interpreted in an idealized or overly formal manner, unless specifically defined herein.

[0067] Furthermore, the use of ordinal numbers such as "first" and "second" in the specification and claims to modify the elements of the claims does not imply or represent any prior ordinal number of the claimed element, nor does it represent the order of one claimed element with another, or the order of manufacturing methods. The use of such ordinal numbers is only to enable a claimed element with a certain name to be clearly distinguished from another claimed element with the same name.

[0068] Furthermore, in some embodiments of this utility model, terms such as "connection" and "interconnection," unless specifically defined, may refer to two structures in direct contact, or they may refer to two structures not in direct contact, with other structures disposed between them. Moreover, these terms regarding joining and connecting may also include situations where both structures are movable or both structures are fixed.

[0069] Please refer to Figure 1 as well as Figure 2 . Figure 1 This is a perspective view of a transformer module 100 according to an embodiment of the present invention, and Figure 2 This is an exploded perspective view of a transformer module 100 according to an embodiment of the present invention. In this embodiment, the transformer module 100 is applicable to high-frequency and high-power-density applications and features a small size and good heat dissipation.

[0070] The transformer module 100 may include a primary side assembly 110, a secondary side assembly 130, a magnetic element 150, and a winding frame 170. The primary side assembly 110 is connected to the secondary side assembly 130, and the winding frame 170 is connected between the primary side assembly 110 and the secondary side assembly 130. A portion of the magnetic element 150 is located in the winding frame 170 and disposed between the primary side assembly 110 and the secondary side assembly 130.

[0071] In this embodiment, the primary side assembly 110 has a first cover 112, a first pillar 114, and a first coil 116. The first pillar 114 is connected to the first cover 112, and the first coil 116 is wound around the first pillar 114. The first cover 112 and the first pillar 114 may be integrally formed and may be made of a magnetically conductive material, such as ferrite or silicon steel sheet, but are not limited thereto.

[0072] Similarly, the secondary side assembly 130 has a second cover 132, a second pillar 134, and a second coil 136. The second pillar 134 is connected to the second cover 132, and the second coil 136 is wound around the second pillar 134. Similarly, the second cover 132 and the second pillar 134 may be integrally formed and may be made of a magnetically conductive material, such as ferrite or silicon steel sheet, but are not limited thereto.

[0073] In this embodiment, the first column 114 extends along a first axis AX 1, and the second column 134 also extends along the first axis AX 1 and is fixedly connected to the first column 114 to form an iron core.

[0074] Please refer to the following: Figures 1 to 3 . Figure 3According to an embodiment of the present invention, the transformer module 100 is arranged along... Figure 1 A three-dimensional cross-sectional view of the midline segment AA. In this embodiment, the size of the first column 114 is larger than the size of the second column 134. Specifically, the first column 114 and the second column 134 can be cylinders. The cross-section of the first column 114 forms a first circle, and the cross-section of the second column 134 forms a second circle, and the diameter DT1 of the first circle is 1.1 to 2 times the diameter DT2 of the second circle.

[0075] Furthermore, in this embodiment, the winding frame 170 is made of a non-conductive and non-magnetic material, such as plastic, but not limited to this. The winding frame 170 may have a first sleeve 171 and a second sleeve 172, which respectively accommodate the first column 114 and the second column 134, and the first coil 116 and the second coil 136 are respectively sleeved on the outer surfaces of the first sleeve 171 and the second sleeve 172.

[0076] The winding frame 170 further includes an intermediate receiving portion 173 connected between the first sleeve 171 and the second sleeve 172, such that the first sleeve 171 is connected to the second sleeve 172 via the intermediate receiving portion 173, and the intermediate receiving portion 173 is configured to receive the magnetic element 150.

[0077] Specifically, the intermediate receiving part 173 has an intermediate receiving space 1731, the magnetic element 150 is disposed in the intermediate receiving space 1731, then the first column 114 passes through the first sleeve 171 into the intermediate receiving space 1731 and then passes through the magnetic element 150, and finally connects to the second column 134.

[0078] It is worth noting that, such as Figure 2 and Figure 3 As shown, the intermediate receiving portion 173 further has four positioning protrusions 1733 protruding toward the magnetic element 150, configured to contact and position the magnetic element 150 to prevent the magnetic element 150 from dislodging from the intermediate receiving portion 173. Figure 2 As shown, each positioning protrusion 1733 can be an elongated protrusion extending along a second axis AX2. The second axis AX2 is perpendicular to the first axis AX1.

[0079] Next, please refer to Figures 2 to 4 . Figure 4 According to an embodiment of the present invention, the transformer module 100 is arranged along... Figure 1 Cross-sectional view of the midline segment BB. In this embodiment, as... Figure 3 and Figure 4 As shown, the magnetic element 150 may have a ring structure and be sleeved on the first column 114 to increase the overall leakage inductance of the transformer module 100.

[0080] It should be noted that the magnetic element 150 is not limited to a closed ring structure; other shapes and configurations are also possible in other embodiments. For example, please refer to... Figure 5 , Figure 5 This is a top cross-sectional view of a transformer module 100 according to another embodiment of the present invention. Figure 5 As shown, the magnetic element 150 has a horseshoe-shaped structure.

[0081] It is worth noting that, in Figure 5 In the diagram, the arrows point in the direction of the magnetic field lines of the first coil 116, and all are located within the range of the magnetic element 150. That is, this configuration does not affect the overall efficiency of the transformer module 100, and further achieves the goal of overall weight reduction.

[0082] Next, please return to Figure 3 In this embodiment, the height HT1 of the first coil 116 on the first axial direction AX1 (Z-axis) is different from the height HT2 of the second coil 136 on the first axial direction AX1.

[0083] Other examples Figure 2 and Figure 3 As shown, the transformer module 100 may further include an auxiliary coil 118, which is sleeved around the first coil 116. The auxiliary coil 118 can be sleeved around the first coil 116 by insulating tape or other adhesive elements, and has no electrical connection with the first coil 116.

[0084] The auxiliary coil 118 is configured to generate an auxiliary power supply. For example, the voltage output by the transformer module 100 is supplied to an external circuit, and the auxiliary power supply is supplied to a controller or control chip used to control said external circuit, such as 10 volts, but not limited thereto.

[0085] It is worth noting that, compared to the existing transformer module where the auxiliary coil is directly sleeved on the first sleeve 171, the auxiliary coil 118 of this utility model can be configured in a way that allows the height HT 1 of the first coil 116 to be increased. Therefore, the first coil 116 can be wound with multiple strands of wire, thereby reducing the overall loss.

[0086] Please refer to the following: Figure 6 . Figure 6 This is a front view schematic diagram of a transformer module 100 according to an embodiment of the present invention. Figure 6In the diagram, arrow LR represents the direction of the magnetic field lines generated by the leakage inductance, while arrow TX represents the direction of the magnetic field lines generated by the first coil 116. Since the leakage inductance is formed on the primary side and its magnetic field lines are located on the primary side, and since the first column 114 of this invention is thicker than the second column 134, the magnetic field lines of the leakage inductance and the magnetic field lines of the first coil 116 will not be excessively concentrated within the range of the first column 114, thereby avoiding the problem of overheating.

[0087] Please refer to the following: Figure 7 and Figure 8 . Figure 7 This is a schematic diagram of the magnetic field lines distribution of the existing transformer module 10, and Figure 8 This is a schematic diagram of the magnetic field distribution of the transformer module 100 according to this utility model. Figure 7 It can be seen that when the primary side column 11 and the secondary side column 13 have the same size, the magnetic field lines on the primary side column 11 will be too concentrated. Figure 7 The red part has a higher magnetic flux density, which generates unnecessary heat and also leads to power loss.

[0088] In this utility model, since the size of the first column 114 is larger than the size of the second column 134, therefore... Figure 8 As shown, the magnetic field lines on the primary side (e.g., within the range of the first column 114) are significantly more uniform, thus avoiding overheating issues and power loss problems.

[0089] It is also worth noting that, for example Figure 8 As shown, the junction 113 of the first column 114 and the first cover 112 forms a right angle structure, so the magnetic lines of force tend to concentrate at the junction 113, resulting in unnecessary heat generation.

[0090] To further improve this problem, in this embodiment, such as Figure 2 and Figure 3 As shown, the transformer module 100 may further include a ring element 180, disposed on the first cover 112 and surrounding the first post 114. Specifically, the ring element 180 is disposed at the junction 113 of the first post 114 and the first cover 112 (it should be noted that...). Figure 8 (Schematic diagram without the collar element 180).

[0091] The collar element 180 can be a ring-shaped object. For example... Figure 3 As shown, when viewed along the second axis AX2, the collar element 180 may have an arc structure, recessed towards the first column 114. Based on this configuration, magnetic lines of force can be avoided from concentrating at the junction 113 (right-angle structure) between the first column 114 and the first cover 112, thereby further improving the overall heat dissipation efficiency.

[0092] In this embodiment, the collar element 180 may be made of ferrite, magnetic disk, or magnetic adhesive tape, or a combination thereof, but is not limited thereto. In some embodiments, the collar element 180 may be integrally formed with the first pillar 114 and the first cover 112.

[0093] In addition, such as Figure 7 As shown, the auxiliary coil 18 of the existing transformer module 10 is sleeved on the primary side column 11, which makes the space available for the primary side coil 15 insufficient. That is, the height of the primary side coil 15 is relatively low. Therefore, the number of strands in a single turn of the primary side coil 15 is less than the number of strands in the first coil 116 of this utility model, resulting in a larger overall power loss.

[0094] In summary, this utility model provides a transformer module 100, including a primary side assembly 110, a secondary side assembly 130, and a magnetic element 150. The first coil 116 of the primary side assembly 110 is sleeved on the outside of the first column 114, and the second coil 136 of the secondary side assembly 130 is sleeved on the outside of the second column 134. The magnetic element 150 is sleeved on either the first column 114 or the second column 134. The first column 114 is fixedly connected to the second column 134, and the diameter DT1 of the first column 114 is 1.1 to 2 times the diameter DT2 of the second column 134.

[0095] Based on this configuration, compared with existing transformer modules, the transformer module 100 of this utility model can reduce power loss by more than 16%. Furthermore, since the size of the first column 114 is larger than that of the second column 134, the leakage inductance of the transformer module 100 and the magnetic lines of force of the first coil 116 can be evenly arranged in the first column 114, thereby reducing the overall temperature and achieving a good heat dissipation effect.

[0096] Additionally, the transformer module 100 may further include a ring element 180 disposed on the first cover 112 and surrounding the first pillar 114. The ring element 180 is located at the junction 113 of the first pillar 114 and the first cover 112, and has an arc-shaped structure, concave towards the first pillar 114. Based on the configuration of the ring element 180, magnetic lines of force can be prevented from concentrating at the junction 113 of the first pillar 114 and the first cover 112, thereby further improving overall heat dissipation efficiency.

[0097] While the embodiments and advantages of this utility model have been disclosed above, it should be understood that anyone skilled in the art can make modifications, substitutions, and refinements without departing from the spirit and scope of this utility model. Furthermore, the scope of protection of this utility model is not limited to the processes, machines, manufacturing, material composition, apparatus, methods, and steps described in the specific embodiments of the specification. Anyone skilled in the art can understand from the disclosure of this utility model any existing or future processes, machines, manufacturing, material composition, apparatus, methods, and steps that can perform substantially the same function or obtain substantially the same results in the embodiments described herein, and can be used according to this utility model. Therefore, the scope of protection of this utility model includes the aforementioned processes, machines, manufacturing, material composition, apparatus, methods, and steps. In addition, each claim constitutes an individual embodiment, and the scope of protection of this utility model also includes combinations of various claim claims and embodiments.

Claims

1. A transformer module, characterized in that: include: A primary side component, having: The first cover body; A first column, connected to the first cover; and A first coil is wound around the first cylinder; Primary and secondary side components, having: A second cover; and A second column, connected to the second cover; and A second coil, wound around the second cylinder; and A magnetic element is disposed between the primary side assembly and the secondary side assembly; The first column is fixedly connected to the second column, and the size of the first column is larger than the size of the second column.

2. The transformer module as described in claim 1, characterized in that: The transformer module further includes a winding frame configured to connect to the primary side assembly and the secondary side assembly. The winding frame has a first sleeve and a second sleeve to accommodate the first column and the second column, respectively, and the first sleeve communicates with the second sleeve.

3. The transformer module as described in claim 2, characterized in that: The winding frame is made of a non-conductive and non-magnetic material.

4. The transformer module as described in claim 3, characterized in that: The winding frame further includes an intermediate receiving portion connected between the first sleeve and the second sleeve, and the intermediate receiving portion is configured to receive the magnetic element.

5. The transformer module as claimed in claim 4, wherein the magnetic element is sleeved on the first column, and the magnetic element has a ring structure or a horseshoe structure.

6. The transformer module as described in claim 4, characterized in that: The intermediate receiving portion has an intermediate receiving space, the magnetic element is disposed in the intermediate receiving space, and the intermediate receiving portion further has at least one positioning protrusion protruding toward the magnetic element and configured to contact the magnetic element and position the magnetic element.

7. The transformer module as described in claim 1, characterized in that: The first cover and the first column are integrally formed, and the first column extends along a first axial direction. The transformer module further includes a ring element disposed on the first cover and covering the first column.

8. The transformer module as described in claim 7, characterized in that: When viewed along a second axis, the collar element has an arcuate structure that is concave toward the first column, and the second axis is perpendicular to the first axis, wherein the collar element is made of ferrite, magnetic disk, magnetic tape, or a combination thereof.

9. The transformer module as described in claim 1, characterized in that: The first column extends along a first axial direction, and the height of the first coil in the first axial direction is greater than the height of the second coil in the first axial direction.

10. The transformer module as described in claim 1, characterized in that: The first column has a cross-section forming a first circle, the second column has a cross-section forming a second circle, and the diameter of the first circle is 1.1 to 2 times the diameter of the second circle.

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