Transformer and wireless charging device using the same

Abstract

A transformer and a wireless charging device using the same, including a lower shell, a support frame, a support body, a plurality of magnetic conductive elements and a coil. The lower shell has an inner wall surrounding the inner surface of the lower shell. The support body and the support frame are buckled to each other and arranged on the inner surface of the lower shell. The magnetic conductive elements are arranged between the support frame and the support body, and the magnetic conductive elements are arranged adjacent to each other, wherein the bottom surface of the magnetic conductive elements is higher than or equal to the top surface of the inner wall. The coil is wound on the support body, and the coil and the magnetic conductive elements are located on opposite sides of the support body.

Description

Technical Field

[0001] This utility model relates to a power transmission system, and more particularly to a transformer and a wireless charging device using the same. Background Technology

[0002] The wireless charging device achieves charging via inductive means, where a main coil is located in the charger base of the transmitter assembly, and a secondary coil is located in the device to be charged in the receiver assembly. When power is applied to the charger base, current flows through the main coil, generating magnetic flux. When the secondary coil of the device to be charged approaches the main coil, the magnetic flux couples to the secondary coil, thereby inducing a current in the secondary coil. The induced current in the secondary coil can be used to charge the battery of the device to be charged.

[0003] However, currently, the magnetic flux generated by the current in both the main coil of the transmitter and the secondary coil of the receiver is not uniform, resulting in poor charging efficiency of wireless charging devices. Utility Model Content

[0004] This utility model relates to a transformer and a wireless charging device using the same, which reduces magnetic leakage and improves charging performance.

[0005] According to one aspect of this utility model, a transformer is provided, comprising a lower housing, a support frame, a support body, a plurality of magnetically conductive elements, and a coil. The lower housing has an inner sidewall surrounding its inner surface. The support body and the support frame are interlocked and disposed on the inner surface of the lower housing. The magnetically conductive elements are disposed between the support frame and the support body, arranged adjacent to each other, wherein the top surface of the magnetically conductive elements is higher than or equal to the top surface of the inner sidewall. The coil is wound on the support body, and the coil and the magnetically conductive elements are located on opposite sides of the support body.

[0006] According to another aspect of this utility model, a wireless charging device is provided, comprising a power cord and a transformer. The power cord provides a power input. The transformer is connected to the power cord to transmit power. The transformer includes a lower housing, a support frame, a support body, a plurality of magnetic elements, and a coil. The lower housing has an inner wall surrounding its inner surface. The support body and the support frame are interlocked and disposed on the inner surface of the lower housing. The magnetic elements are disposed between the support frame and the support body, arranged adjacent to each other, wherein the top surface of the magnetic elements is higher than or equal to the top surface of the inner wall. The coil is wound on the support body, and the coil and the magnetic elements are located on opposite sides of the support body.

[0007] To provide a better understanding of the above and other aspects of this utility model, specific embodiments are described below in conjunction with the accompanying drawings: Attached Figure Description

[0008] Figure 1 This is a circuit diagram of a wireless charging device according to an embodiment of the present invention;

[0009] Figure 2A This is a perspective view of a transformer according to an embodiment of the present invention;

[0010] Figure 2B and Figure 2C They are respectively Figure 2A A breakdown diagram of a transformer from different perspectives;

[0011] Figure 3 This is a top view of the lower surface of the upper housing according to an embodiment of the present invention;

[0012] Figure 4 This is a top view of the upper surface of the lower housing according to an embodiment of the present invention;

[0013] Figure 5 This is a top view of a support frame and support body interlocked and combined above the lower shell according to an embodiment of the present utility model;

[0014] Figure 6 This is a cross-sectional view of a transformer at the buckle according to an embodiment of the present invention;

[0015] Figure 7 and Figure 8 These are cross-sectional schematic diagrams of a transformer at the screw fastening point according to an embodiment of the present invention;

[0016] Figure 9 A schematic diagram showing the magnetic conductive elements and support frame mounted on the lower housing;

[0017] In the attached figures, the following labels are used:

[0018] 100: Wireless charging device

[0019] 110: Transmitter assembly

[0020] 111: First power line

[0021] 112: First Transformer

[0022] 113: Main coil

[0023] 120: Receiver assembly

[0024] 121: Second power line

[0025] 122: Second Transformer

[0026] 123: Secondary coil

[0027] 130: Power source

[0028] 131: Power Module

[0029] 132: Control Circuit

[0030] 140: Load

[0031] 200: Transformer

[0032] 202: Upper shell

[0033] 203: Through-hole

[0034] 204: Locking fastener

[0035] 205: Convex Rib

[0036] 210: Support body

[0037] 210a: First side

[0038] 210b: Second side

[0039] 210c: Perforation

[0040] 211: Winding slot

[0041] 213: Through-hole

[0042] 214: Locking hardware

[0043] 215: Hook

[0044] 215a: Rod

[0045] 215b: Hook radical

[0046] 220, 221: Magnetic elements

[0047] 220a: Top surface

[0048] 220b: Bottom surface

[0049] 222: Gap

[0050] 230: Coil

[0051] 232: Threading

[0052] 232a: Outgoing cable terminal

[0053] 240: Support frame

[0054] 242: Outgoing cable end fixing bracket

[0055] 244: Long slotted section

[0056] 245: Card Hole

[0057] 246: Positioning component

[0058] 248, 249: Thermal conductive medium

[0059] 250: Lower housing

[0060] 251: Inner wall

[0061] 252: Heat dissipation fins

[0062] 253: Concave surface

[0063] 253a: Deep trench

[0064] 253b: Deep accommodating groove

[0065] 254: Outer ring surface

[0066] 255: Screw hole

[0067] 256: Screw hole

[0068] 257: Separator ring

[0069] H1: First Height

[0070] H2: Second Altitude

[0071] H3: Third altitude. Detailed Implementation

[0072] Please refer to Figure 1 This is a circuit diagram of a wireless charging device 100. The wireless charging device 100 includes a transmitter assembly 110 and a receiver assembly 120. The transmitter assembly 110 includes a first power line 111 and a first transformer 112. The receiver assembly 120 includes a second power line 121 and a second transformer 122. The transmitter assembly 110 is connected to a power source 130 via the first power line 111, while the receiver assembly 120 is connected to a load 140 (e.g., the battery of the device to be charged) via the second power line 121. When the power source 130 applies power to the transmitter assembly 110, the current flows through the main coil 113 of the first transformer 112, generating a magnetic flux. When the secondary coil 123 of the second transformer 122 approaches the main coil 113, the magnetic flux couples to the secondary coil 123, thereby inducing a current in the secondary coil 123. Therefore, the induced current in the secondary coil 123 can charge the battery of the device to be charged. In other words, the wireless charging device 100 can achieve wireless transmission of electrical signals through near-field magnetic coupling.

[0073] The power source 130 may include a power module 131 and a control circuit 132, the control circuit 132 being used to control the voltage and current output by the power module 131. A first power line 111 is electrically connected to the power source 130 to provide a power input. A first transformer 112 is connected to the first power line 111, and the first transformer 112 can transmit power to the second transformer 122 of the receiver assembly 120 via near-field magnetic coupling. The internal structure of the transformers will be described below. Since the internal structures of the first transformer 112 and the second transformer 122 are similar, the following description is not limited to the first transformer 112 or the second transformer 122.

[0074] Please refer to Figures 2A to 5 ,in Figure 2A This is a perspective view of a transformer 200 according to an embodiment of the present invention. Figure 2B and Figure 2C These are exploded schematic diagrams of a transformer 200 according to an embodiment of the present invention, viewed from different angles. Figure 3 This is a top view of the inner surface of the upper housing 202 according to an embodiment of the present invention. Figure 4 This is a top view of the inner surface of the lower housing 250 according to an embodiment of the present invention. Figure 5 This is a top view of a support frame 240 and support body 210 interlocked and disposed above the lower housing 250 according to an embodiment of the present invention. The transformer 200 may be the first transformer 112 or the second transformer 122 described above. The transformer 200 may be disposed in a ground / wall assembly and / or a vehicle assembly, the ground / wall assembly having a transmitter assembly and the vehicle assembly having a receiver assembly. The ground / wall assembly and the vehicle assembly can be wirelessly charged via near-field magnetic coupling. The vehicle assembly may include an automated guided vehicle or an autonomous mobile robot, etc.

[0075] In one embodiment, the transformer 200 includes an upper housing 202, a support body 210, a plurality of magnetically conductive elements 220, a coil 230, a support frame 240, and a lower housing 250. In this embodiment, the lower housing 250 is the first housing, and the upper housing 202 is the second housing. The upper housing 202 may be a plastic housing, while the lower housing 250 may be a metal housing. The upper housing 202 and the lower housing 250 are disposed opposite to each other to accommodate the support body 210, the magnetically conductive elements 220, the coil 230, and the support frame 240 therein. The support body 210 may be a winding frame, with a winding slot 211 on one side for accommodating the coil 230. Figure 2BAs shown, the support body 210 has a first side 210a, a second side 210b, and at least one through hole 210c passing through both the first side 210a and the second side 210b. However, the through hole 210c may be omitted or replaced by other structural forms. Magnetic conductive elements 220 are disposed on the first side 210a of the support body 210, that is, between the support body 210 and the support frame 240, and these magnetic conductive elements 220 are arranged adjacent to each other. In addition, a coil 230 is wound on the second side 210b of the support body 210, that is, wound in the winding groove 211, and the internal winding of the coil 230 includes a through wire 232 entering the first side 210a of the support body 210 through the through hole 210c, as shown in Figures 2B, 2C, and 5.

[0076] The magnetic elements 220 are, for example, iron cores, which may be made of ferrite cores. These magnetic elements 220 are arranged, for example, in a grid pattern or other shapes, with each magnetic element 220 adjacent to each other, and the size of the magnetic elements 220 is adjustable. For example, to allow the thread 232 to pass through the through-hole 210c into the first side 210a of the support body 210, at least one of the magnetic elements 220 221 forms a notch 222 at the position corresponding to the through-hole 210c, the notch 222 for the thread 232 to pass through. Therefore, the thread 232 can pass downwards at an angle through the notch 222 of the magnetic element 220 and enter the region located below the notch 222.

[0077] In one embodiment, the guide wire 232 can be formed of stranded wire or flexible flat wire. The number of strands and wire diameter of the guide wire 232 can be selected appropriately according to the current requirements, and the stranded wire has high compliance when passing through the notch 222, thereby reducing losses and mechanical stress. Furthermore, the stranded wire can effectively reduce skin effect and proximity effect losses at high frequencies, making it suitable for the operating frequency of wireless charging. In addition, the placement of a small-sized magnetic conductive element 221 around the guide wire 232 can prevent magnetic flux leakage and maintain magnetic field concentration, thus avoiding magnetic flux divergence caused by an excessively large notch 222.

[0078] Please refer to Figure 2B , 2C 5. The transformer 200 may include a terminal fixing bracket 242, which is disposed on one side of the support frame 240 for fixing a terminal 232a of the wire 232. Therefore, the terminal 232a of the wire 232 can be fixed to one side of the support frame 240 by the terminal fixing bracket 242 to serve as a power input or output terminal.

[0079] Furthermore, the thread 232 is extendably disposed within an elongated slot 244 of the support frame 240, such that the thread 232 extends substantially horizontally. Additionally, the lower housing 250 is disposed on the bottom surface of the support frame 240, meaning the support frame 240 is positioned between the lower housing 250 and the magnetically conductive element 220. The outer surface of the lower housing 250 has multiple heat dissipation fins 252 to improve the heat dissipation efficiency of the transformer 200. Furthermore, the inner surface of the lower housing 250 has a deep groove 253a, the position and extension direction of which correspond to the elongated slot 244, allowing the thread 232 extending below the support frame 240 to be fixed to the outlet end fixing bracket 242 via the deep groove 253a.

[0080] Please refer to Figure 2B , 3 4 and 7, the peripheral surface of the upper housing 202 is provided with a plurality of through holes 203, while the peripheral surface (i.e., the outer annular surface 254) of the lower housing 250 is provided with a plurality of screw holes 255 corresponding to the through holes 203. A plurality of fasteners 204 (e.g., screws) can individually pass through the corresponding through holes 203 and be locked in the corresponding screw holes 255 to engage the upper housing 202 and the lower housing 250. Furthermore, to accommodate the support frame 240 and the heat-conducting medium 248, the lower housing 250 has an inner sidewall 251 for defining a concave surface 253 and an outer annular surface 254. The inner sidewall 251 surrounds the inner surface of the lower housing 250. The inner sidewall 251 is substantially perpendicularly connected between the concave surface 253 and the outer annular surface 254, and the inner sidewall 251 is a closed annular structure, so that the inner surface of the lower housing 250 has a shallow groove. Therefore, the support frame 240 and the heat-conducting medium 248 can be disposed in a shallow groove.

[0081] In addition, the inner surface of the lower housing 250 also has another deep receiving groove 253b for accommodating the cable end fixing bracket 242, so that the cable end fixing bracket 242 can be covered between the upper housing 202 and the lower housing 250.

[0082] Please refer to Figure 2B , 4 5 and 8, the support body 210 has multiple through holes 213 around its perimeter, while the concave surface 253 of the lower housing 250 near the inner sidewall 251 has multiple screw holes 256 corresponding to the through holes 203. Multiple fasteners 214 (e.g., screws) can individually pass through the corresponding through holes 213 and be locked in the corresponding screw holes 256 to connect the support body 210 to the lower housing 250. Please refer to... Figure 5 and Figure 6In one embodiment, when the support body 210 is fixed to the lower housing 250 by the fastener 214, in order to improve waterproofing, the inner wall 251 and the outer ring surface 254 of the lower housing 250 can be isolated by a partition ring 257. That is, the partition ring 257 is located outside the inner wall 251, so that water vapor cannot seep into the interior of the lower housing 250 through the outer ring surface 254.

[0083] Please refer to Figure 3 , 4 and 6, of which Figure 6 for Figure 5 The diagram shows a cross-sectional view of the transformer 200 at the snap-fit ​​point. The upper housing 202 may have a protruding rib 205 relative to the partition ring 257 of the lower housing 250. The rib extends downward from the inner surface of the upper housing 202 to the partition ring 257 of the lower housing 250, and may not abut against the bottom surface of the partition ring 257 or may abut directly against it. Since the protruding rib 205 is a closed ring structure, it forms a closed water-blocking structure with the partition ring 257 of the lower housing 250, similar to a waterproof ring, preventing moisture from seeping into the interior of the lower housing 250 through the outer ring surface 254. Furthermore, the interior of the partition ring 257 of the lower housing 250 may be filled with a sealing material (not shown), such as glue or a polymer, further enhancing the overall waterproof performance of the transformer 200.

[0084] Please refer to Figure 2B , 2C 6. The support body 210 is surrounded by multiple hooks 215 for engaging the support frame 240, and the support frame 240 is surrounded by multiple holes 245 corresponding to the hooks 215, so that the support body 210 and the support frame 240 can be joined. The positions of the hooks 215 and the holes 245 are interchangeable, and their structure is not limited to that shown in this figure. Figure 6 As shown, the rod 215a of the hook 215 extends downward from the side of the support body 210 to the side of the support frame 240, and the hook portion 215b of the hook 215 extends from the end of the rod 215a into the interior of the support frame 240 and is embedded in the locking hole 245, so that the hook 215 and the locking hole 245 are engaged. In addition, the support body 210 and the support frame 240 can also be aligned with each other by positioning members 246 provided around the support frame 240. Then, the assembled support body 210 and support frame 240 are fixed to the lower housing 250.

[0085] In one embodiment, to improve the heat dissipation efficiency of the transformer 200, before fixing the assembled support body 210 and support frame 240 onto the lower housing 250, a thermally conductive medium 248 can be applied or filled onto the concave surface 253 defined by the inner sidewall 251. The thermally conductive medium 248 is, for example, a thermal interface material (TIM) to reduce the contact thermal resistance between the support frame 240 and the lower housing 250. The thermally conductive medium 248 can be a solid or semi-solid liquid, such as a heat dissipation pad or silicone grease containing an adhesive. Silicone grease is a white, viscous paste used to reduce the contact thermal resistance between the support frame 240 and the lower housing 250, thereby improving heat dissipation efficiency.

[0086] In addition, please refer to Figure 2B and 2C To improve the heat dissipation efficiency of the transformer 200, a thermally conductive medium 249 may be applied or filled between the magnetic element 220 and the support body 210 before assembling the support body 210 and the support frame 240. The thermally conductive medium 249 may be, for example, a thermal interface material (TIM) to reduce the contact thermal resistance between the support body 210 and the magnetic element 220. The thermally conductive medium 249 may be a solid or a semi-solid liquid, such as a heat dissipation pad or silicone grease containing an adhesive. Silicone grease is a white, viscous paste used to reduce the contact thermal resistance between the support body 210 and the magnetic element 220, thereby improving heat dissipation efficiency.

[0087] Please refer to Figure 9 This is a schematic diagram showing the magnetic element 220 and support frame 240 disposed on the lower housing 250. The magnetic element 220 and support frame 240 are stacked on the concave surface 253 of the lower housing 250. The magnetic element 220 has a top surface 220a and a bottom surface 220b. The top surface 220a of the magnetic element 220 is higher than the outer ring surface 254 of the lower housing 250, while the bottom surface 220b of the magnetic element is higher than or equal to the outer ring surface 254 of the lower housing 250. Therefore, the height of the outer ring surface 254 and the inner sidewall 251 is approximately lower than the bottom surface 220b of the magnetic element 220, or the outer ring surface 254 is at the same height as the bottom surface 220b of the magnetic element 220.

[0088] like Figure 9As shown, the outer annular surface 254 (or inner sidewall 251) has a first height H1 relative to the concave surface 253 of the lower housing 250, while the bottom surface 220b of the magnetic element 220 has a second height H2 relative to the concave surface 253 of the lower housing 250, and the top surface 220a of the magnetic element 220 has a third height H3 relative to the concave surface 253 of the lower housing 250. The third height H3 is greater than the second height H2, and the second height H2 is greater than or equal to the first height H1. Therefore, the magnetic lines of force of the magnetic element 220 will not be blocked by the inner sidewall 251 of the lower housing 250, thus preventing magnetic loss. Furthermore, due to the reduced height of the outer annular surface 254 and the inner sidewall 251, the overall assembly thickness of the transformer 200 can be reduced, achieving a thinner and lighter design.

[0089] In summary, although the present invention has been disclosed above with reference to embodiments, it is not intended to limit the present invention. Those skilled in the art to which this invention pertains can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of this invention shall be determined by the appended claims.

Claims

1. A transformer, characterized in that: include: A first housing having an inner sidewall surrounding the inner surface of the first housing; A support frame; A support body is fastened to the support frame and disposed on the inner surface of the first housing; Multiple magnetically conductive elements are disposed between the support frame and the support body, arranged adjacent to each other, wherein the bottom surface of the magnetically conductive elements is higher than or equal to the top surface of the inner wall; and A coil is wound on one side of the support body, and the coil and the magnetic conductive elements are located on opposite sides of the support body.

2. The transformer as described in claim 1, characterized in that: The support body includes a through hole, and the coil includes a wire that enters the support body from the through hole on one side of the support body relative to the support frame.

3. The transformer as described in claim 2, characterized in that: At least one of these magnetic elements has a notch formed at the position corresponding to the perforation.

4. The transformer as described in claim 2, characterized in that: It also includes a cable end fixing bracket, which is set on one side of the support frame, and one end of the cable passes through the hole and is fixed to the cable end fixing bracket.

5. The transformer as described in claim 1, characterized in that: The support body is a winding frame, and a winding groove is provided on one side to accommodate the coil.

6. The transformer as described in claim 1, characterized in that: The inner wall defines a concave surface and an outer annular surface. The inner wall is perpendicularly connected between the concave surface and the outer annular surface, and the inner wall is a closed annular structure.

7. The transformer as described in claim 6, characterized in that: The support body has multiple through holes around its perimeter, and the concave surface near the inner wall has multiple screw holes corresponding to these through holes.

8. The transformer as described in claim 7, characterized in that: It also includes multiple locking fasteners, which individually pass through the corresponding through holes and are locked in the corresponding screw holes.

9. The transformer as described in claim 1, characterized in that: The support frame is surrounded by multiple positioning elements, and the support body and the support frame are aligned with each other through these positioning elements.

10. The transformer as described in claim 6, characterized in that: The inner wall of the first housing is separated from the outer annular surface by a partition ring.

11. The transformer as described in claim 10, characterized in that: It further includes a second housing, which is disposed opposite to the first housing, and the second housing has a protruding rib relative to the partition ring. The protruding rib extends from the second housing to the partition ring and is a closed ring structure.

12. The transformer as described in claim 6, characterized in that: The outer annular surface has a first height relative to the concave surface, the bottom surface of the magnetic elements has a second height relative to the concave surface, and the top surface of the magnetic elements has a third height relative to the concave surface, wherein the third height is greater than the second height, and the second height is greater than or equal to the first height.

13. The transformer as described in claim 1, characterized in that: The support body is provided with multiple hooks around its perimeter for locking the support frame, and the support frame is provided with multiple locking holes corresponding to these hooks around its perimeter.

14. The transformer as described in claim 1, characterized in that: It also includes a heat-conducting medium disposed between the support frame and the first housing.

15. The transformer as described in claim 1, characterized in that: It also includes a thermally conductive medium disposed between the support body and the magnetically conductive elements.

16. A wireless charging device, characterized in that: include: A power cord, used to provide a power input; as well as A transformer, connected to the power line to transmit the power, the transformer comprising: A first housing having an inner sidewall surrounding the inner surface of the first housing; A support frame; A support body is fastened to the support frame and disposed on the inner surface of the first housing; Multiple magnetically conductive elements are disposed between the support frame and the support body, arranged adjacent to each other, wherein the bottom surface of the magnetically conductive elements is higher than the top surface of the inner wall; and A coil is wound on one side of the support body, and the coil and the magnetic conductive elements are located on opposite sides of the support body.

17. The wireless charging device as described in claim 16, characterized in that: The support body includes a through hole, and the coil includes a wire that enters the support body from the through hole on one side of the support body relative to the support frame.

18. The wireless charging device as described in claim 17, characterized in that: At least one of these magnetic elements has a notch formed at the position corresponding to the perforation.

19. The wireless charging device as described in claim 17, characterized in that: It also includes a cable end fixing bracket, which is set on one side of the support frame, and one end of the cable passes through the hole and is fixed to the cable end fixing bracket.

20. The wireless charging device as described in claim 16, characterized in that: The support body is a winding frame, and a winding groove is provided on one side to accommodate the coil.

21. The wireless charging device as described in claim 16, characterized in that: The inner wall defines a concave surface and an outer annular surface. The inner wall is perpendicularly connected between the concave surface and the outer annular surface, and the inner wall is a closed annular structure.

22. The wireless charging device as described in claim 21, characterized in that: The support body has multiple through holes around its perimeter, and the concave surface near the inner wall has multiple screw holes corresponding to these through holes.

23. The wireless charging device as described in claim 22, characterized in that: It also includes multiple locking fasteners, which individually pass through the corresponding through holes and are locked in the corresponding screw holes.

24. The wireless charging device as described in claim 16, characterized in that: The support frame is surrounded by multiple positioning elements, and the support body and the support frame are aligned with each other through these positioning elements.

25. The wireless charging device as described in claim 21, characterized in that: The inner wall of the first housing is separated from the outer annular surface by a partition ring.

26. The wireless charging device as described in claim 25, characterized in that: It further includes a second housing, which is disposed opposite to the first housing, and the second housing has a protruding rib relative to the partition ring. The protruding rib extends from the second housing to the partition ring and is a closed ring structure.

27. The wireless charging device as claimed in claim 21, characterized in that: The outer annular surface has a first height relative to the concave surface, the bottom surface of the magnetic elements has a second height relative to the concave surface, and the top surface of the magnetic elements has a third height relative to the concave surface, wherein the third height is greater than the second height, and the second height is greater than or equal to the first height.

28. The wireless charging device as described in claim 16, characterized in that: The support body is provided with multiple hooks around its perimeter for locking the support frame, and the support frame is provided with multiple locking holes corresponding to these hooks around its perimeter.

29. The wireless charging device as described in claim 16, characterized in that: It also includes a heat-conducting medium disposed between the support frame and the first housing.

30. The wireless charging device as described in claim 16, characterized in that: It also includes a thermally conductive medium disposed between the support body and the magnetically conductive elements.

Images