Transformer

Abstract

To provide a transformer that realizes a simple manufacturing process, easy automation, stable product quality and dimension, great product commonality, and small volume.SOLUTION: A transformer includes a core 2 including first and second magnetic materials 21, 22, a bobbin 3, an inner first coil 41, an outer first coil 41, a second coil, and at least one circuit board 5, 6. A bobbin includes a bobbin main body 31, a bobbin through-hole 32, and a winding space portion 33. The bobbin through-hole runs through opposite sides of the bobbin main body. The winding space portion is formed on an outer peripheral surface of the bobbin main body. The inner and outer first coils are wound around the winding space portion. The inner first coil is positioned between the outer first coil and the outer peripheral surface of the bobbin main body. The second coil is wound around the winding space portion, and positioned between the inner and outer first coils. At least one circuit board has a circuit board through-hole 52, 62 connected to the bobbin through-hole. The core partially penetrates through the bobbin through-hole and the circuit board through-hole.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a transformer, particularly a transformer that forms a coil using a circuit board.

Background Art

[0002] In the field of industrial power, the power consumption of motors accounts for more than 65% of the total industrial power consumption. Motors using frequency converters can save more than 40% of power consumption and reduce carbon dioxide emissions. Also, by adjusting the speed of the motor with a frequency converter, power loss can be significantly reduced, the impact on the power grid caused by the starting current can be reduced, the wear of the motor and other mechanical equipment can be reduced, and maintenance costs can be reduced. Thus, improving the performance of the frequency converter can improve the overall performance of the motor.

[0003] The transformers in frequency converters usually adopt a multi-coil design for different functions. Each coil of the multi-coils of conventional transformers is wound around the core in an irregular arrangement. Therefore, the actual operating voltage of the transformer is likely to drift, the manufacturing process is complex and automation cannot be achieved. Thus, conventional transformers have drawbacks such as increased cost of manual installation, reduced efficiency of industrial automation, and instability of product characteristics and dimensions.

[0004] Therefore, how to develop a transformer that overcomes the above drawbacks has become an urgent task at present.

Summary of the Invention

Problems to be Solved by the Invention

[0005] An object of the present invention is to provide a transformer in which an inner first coil is located between an outer first coil and the outer peripheral surface of a bobbin body, and a second coil is located between the inner first coil and the outer first coil, that is, the outer first coil, the second coil, and the inner first coil are sequentially provided in the stacking direction. By arranging the inner first coil, the outer first coil, and the second coil of the transformer of the present invention as described above, the leakage inductance of the transformer can be significantly reduced, and since the arrangement of the inner first coil, the outer first coil, and the second coil of the transformer is sequential and difficult to wind alternately, the transformer of the present invention has the advantages of a simple manufacturing process, easy realization of automation, stable product quality and dimensions, high product commonality, and small volume.

Means for Solving the Problems

[0006] To achieve the above object, an embodiment of the present invention is a transformer including a core, a bobbin, an inner first coil, an outer first coil, a second coil, and at least one circuit board. The core includes a first magnetic body and a second magnetic body. The bobbin includes a bobbin body, a bobbin through-hole, and a winding space portion. The bobbin through-hole penetrates both opposite surfaces of the bobbin body, and the winding space portion is formed on the outer peripheral surface of the bobbin body. The inner first coil and the outer first coil are wound on the winding space portion, and the inner first coil is located between the outer first coil and the outer peripheral surface of the bobbin body. The second coil is wound on the winding space portion and is located between the inner first coil and the outer first coil. The at least one circuit board has a circuit board through-hole connected to the bobbin through-hole, and a part of the core penetrates the circuit board through-hole and the bobbin through-hole.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Best Mode for Carrying Out the Invention

[0008] Some exemplary embodiments showing the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention can be modified in various ways without departing from the scope of the present invention, and the description and drawings are used essentially for explanatory purposes and are not intended to limit the present invention.

[0009] Referring to FIGS. 1, 2, and 3, FIG. 1 is a schematic diagram of the combined structure of a transformer according to a first embodiment of the present invention, FIG. 2 is a schematic exploded view of the transformer shown in FIG. 1, and FIG. 3 is a schematic partial cross-sectional view of the transformer shown in FIG. 1 along the A-A' direction. As shown in FIGS. 1 to 3, the transformer 1 includes a core 2, a bobbin 3, two first coils 41 (i.e., an inner first coil 41 and an outer first coil 41), a second coil 42, a first circuit board 5, and a second circuit board 6.

[0010] The core 2 includes a first magnetic body 21 and a second magnetic body 22. In the present embodiment, as shown in FIG. 2, the first magnetic body 21 includes a first main surface 211, a first side surface 212, a second side surface 213, and a first intermediate column 214. The first side surface 212 and the second side surface 213 are respectively connected to opposite ends of the first main surface 211 and are located on opposite sides of the transformer 1. The first intermediate column 214 is connected to the first main surface 211 and is located between the first side surface 211 and the second side surface 212. The second magnetic body 22 includes a second main surface 221, a third side surface 222, a fourth side surface 223, and a second intermediate column 224. The second main surface 221 and the first main surface 211 are respectively located on opposite sides of the transformer 1. The third side surface 222 and the fourth side surface 223 are respectively connected to opposite ends of the second main surface 221 and are located on opposite sides of the transformer 1. The third side surface 222 is spatially installed corresponding to the first side surface 212 and is located between the second main surface 221 and the first main surface 211. The fourth side surface 223 is spatially installed corresponding to the second side surface 213 and is located between the second main surface 221 and the first main surface 211. The second intermediate column 224 is connected to the second main surface 221 and is located between the third side surface 222 and the fourth side surface 223. The second intermediate column 224 is spatially installed corresponding to the first intermediate column 214 and is located between the second main surface 221 and the first main surface 211.

[0011] The winding frame 3 includes a winding frame body 31, a winding frame through hole 32, and at least one winding space portion 33. For the sake of simplifying the drawings, the structural features of the core 2 are not shown in FIG. 3. As shown in FIGS. 2 and 3, the winding frame body 31 has a first wall surface 311, a second wall surface 312, and an outer peripheral surface 313. The first wall surface 311 and the second wall surface 312 of the winding frame body 31 are installed at opposite ends of the winding frame body. The first wall surface 311 is located between the first main surface 211 of the first magnetic body 21 and the second wall surface 312. The second wall surface 312 is located between the second main surface 221 of the second magnetic body 22 and the first wall surface 311. The outer peripheral surface 313 of the winding frame body 31 is located between the first wall surface 311 and the second wall surface 312. As shown in FIGS. 2 and 3, the first wall surface 311 of the winding frame body 31 protrudes from the corresponding outer peripheral surface 313, and the second wall surface 312 of the winding frame body 31 protrudes from the corresponding outer peripheral surface 313. The number of winding space portions 33 of the winding frame 3 in this embodiment is one. The winding space portion 33 is defined by the first wall surface 311 protruding from the outer peripheral surface 313, the second wall surface 312 protruding from the outer peripheral surface 313, and the outer peripheral surface 313. Thereby, the winding space portion 33 is formed on the outer peripheral surface 313 of the winding frame body 31. The winding frame body 31 has a hollow structure, and the hollow structure forms the winding frame through hole 32. The winding frame through hole 32 penetrates the first wall surface 311 and the second wall surface 312 of the winding frame body 31.

[0012] Both the inner first coil 41 and the outer first coil 41 constitute a part of the primary coil of the transformer 1, are wound around the winding space portion 33. The inner first coil 41 is wound around the winding space portion 33 and is located between the outer first coil 41 and the outer peripheral surface 313 of the winding frame body 31. The second coil 42 constitutes a part of the secondary coil of the transformer 1, is wound around the inner first coil 41 and around the winding space portion 33. The second coil 42 is located between the inner first coil and the outer first coil, that is, the outer first coil 41, the second coil 42, and the inner first coil 41 are sequentially provided in the stacking direction.

[0013] The wiring within the first circuit board 5 forms the other part of the primary coil of the transformer 1. As shown in FIG. 1, the first circuit board 5 is positioned between the first main surface 211 of the first magnetic body 21 and the first wall surface 311 of the winding frame body 31, and is also positioned between the first main surface 211 of the first magnetic body 21 and the second circuit board 6. The first circuit board 5 has a first circuit board main body 51 and a first circuit board through-hole 52. The first circuit board through-hole 52 penetrates the first circuit board main body 51 and spatially corresponds to the winding frame through-hole 32. The wiring within the second circuit board 6 forms the other part of the secondary coil of the transformer 1. As shown in FIGS. 1 and 2, the second circuit board 6 is positioned between the second main surface 221 of the second magnetic body 22 and the second wall surface 312 of the winding frame body 31, and is also positioned between the second main surface 221 of the second magnetic body 22 and the first circuit board 5. The second circuit board 6 has a second circuit board main body 61 and a second circuit board through-hole 62. The second circuit board through-hole 62 penetrates the second circuit board main body 61 and spatially corresponds to the winding frame through-hole 32. The first circuit board through-hole 52, the second circuit board through-hole 62, and the winding frame through-hole 32 are in communication. The first intermediate column 214 of the first magnetic body 21 of the core 2 penetrates the first circuit board through-hole 52 and the winding frame through-hole 32, and the second intermediate column 224 of the second magnetic body 22 of the core 2 penetrates the second circuit board through-hole 62 and the winding frame through-hole 32. Since the first intermediate column 214 of the first magnetic body 21 and the second intermediate column 224 of the second magnetic body 22 are connected to each other within the winding frame through-hole 32, the inner first coil 41, the outer first coil 41, and the second coil 42 are also wound around the first intermediate column 214 of the first magnetic body 21 and the second intermediate column 224 of the second magnetic body 22. The first side surface 212 of the first magnetic body 21 is connected to the third side surface 222 of the second magnetic body 22, and the second side surface 213 of the first magnetic body 21 is connected to the fourth side surface 223 of the second magnetic body 22, thereby assembling the transformer 1 (as shown in FIG. 1).

[0014] As can be seen from the above, the inner first coil 41 of the transformer 1 of the present invention is located between the outer first coil 41 and the outer peripheral surface 313 of the winding frame body 31, and the second coil 42 is located between the inner first coil and the outer first coil. That is, since the outer first coil 41, the second coil 42, and the inner first coil 41 are sequentially provided in the stacking direction, while each coil of the conventional transformer is irregularly wound around the core, the inner first coil 41, the outer first coil 41, and the second coil 42 of the transformer 1 of the present invention are arranged as described above, so that the leakage inductance of the transformer 1 can be significantly reduced. In addition, since the arrangement of the inner first coil 41, the outer first coil 41, and the second coil 42 in the transformer 1 is sequential and difficult to be wound alternately, the transformer 1 of the present invention has the advantages that the manufacturing process is simple, easy to realize automation, the product quality and dimensions are stable, the product commonality is high, and the volume is small.

[0015] Referring again to FIGS. 1 and 2, the winding frame body 31 further has a first insertion portion 314 and a second insertion portion 315. The first insertion portion 314 and the second insertion portion 315 are respectively installed on opposite sides of the winding frame body 31. The first insertion portion 314 is connected to one end of the first wall surface 311 of the winding frame body 31 and is installed offset from the winding frame through hole 32 without covering the winding frame through hole 32. When the transformer 1 is assembled, that is, when the first intermediate column 214 of the first magnetic body 21 of the core 2 penetrates through the first circuit board through hole 52 and the winding frame through hole 32, and the second intermediate column 224 of the second magnetic body 22 of the core 2 penetrates through the second circuit board through hole 62 and the winding frame through hole 32, and the first intermediate column 214 of the first magnetic body 21 and the second intermediate column 224 of the second magnetic body 22 are connected to each other within the winding frame through hole 32, as shown in FIG. 1, the first insertion portion 314 is adjacent to the first main surface 211 of the first magnetic body 21, and the edge of the first insertion portion 314 is located on the same plane as the first main surface 211, and the plane is parallel to the first wall surface 311 of the winding frame body 31. In this embodiment, the first insertion portion 314 further has a first concave portion 316 in which the top surface of the first insertion portion 314 is recessed and a first insertion hole 317 is provided. The second insertion portion 315 is connected to one end of the second wall surface 312 of the winding frame body 31 and is installed offset from the winding frame through hole 32 without covering the winding frame through hole 32. When the transformer 1 is assembled, that is, when the first intermediate column 214 of the first magnetic body 21 of the core 2 penetrates through the first circuit board through hole 52 and the winding frame through hole 32, and the second intermediate column 224 of the second magnetic body 22 of the core 2 penetrates through the second circuit board through hole 62 and the winding frame through hole 32, and the first intermediate column 214 of the first magnetic body 21 and the second intermediate column 224 of the second magnetic body 22 are connected to each other within the winding frame through hole 32, as shown in FIG. 1, the second insertion portion 315 is adjacent to the second main surface 221 of the second magnetic body 22, and the edge of the second insertion portion 315 is located on the same plane as the second main surface 221, and the plane is parallel to the second wall surface 312 of the winding frame body 31. In this embodiment, the second insertion portion 315 further has a second concave portion 318 in which the top surface of the second insertion portion 315 is recessed and a second insertion hole is provided. Although the position of the second insertion hole is not shown in FIG. 2, it is obvious that the installation position of the second insertion hole corresponds to the installation position of the first insertion hole 317.

[0016] Referring to FIG. 2 again, in this embodiment, the first circuit board body 51 includes an integrally formed first sub-body 511 and a second sub-body 512. The width W1 of the first sub-body 511 is smaller than the width W2 of the second sub-body 512, and the first circuit board through hole 52 is located in the first sub-body 511. Since the first circuit board body 51 is inserted into the first insertion hole 317 through the bottom surface of the first insertion portion 314, at least a part of the first sub-body 511 is located in the first concave portion 316, and at least a part of the second sub-body 512 is located on the bottom surface of the first insertion portion 314. The first sub-body 511 of the first circuit board body 51 is located between the first wall surface 311 of the winding frame body 31 and the first main surface 211 of the first magnetic body 21. The first circuit board through hole 52 communicates with the winding frame through hole 32, so that the first intermediate column 214 of the first magnetic body 21 sequentially passes through the first circuit board through hole 52 and the winding frame through hole 32. The second circuit board body 61 includes an integrally formed third sub-body 611 and a fourth sub-body 612. The width W3 of the third sub-body 611 is smaller than the width W4 of the fourth sub-body 612, and the second circuit board through hole 62 is located in the third sub-body 611. Since the second circuit board body 61 is inserted into the second insertion hole through the bottom surface of the second insertion portion 315, at least a part of the third sub-body 611 is located in the second concave portion, and at least a part of the fourth sub-body 612 is located on the bottom surface of the second insertion portion 315. The third sub-body 611 of the second circuit board body 61 is located between the second wall surface 312 of the winding frame body 31 and the second main surface 221 of the second magnetic body 22. The second circuit board through hole 62 communicates with the winding frame through hole 32, so that the second intermediate column 224 of the second magnetic body 22 sequentially passes through the second circuit board through hole 62 and the winding frame through hole 32. In some embodiments, the width W2 of the second sub-body 512 is less than or equal to the width W1 of the first sub-body 511, whereby the first circuit board body 51 can be inserted into the first insertion hole 317 through the top surface of the first insertion portion 314. The width W4 of the fourth sub-body 612 is less than or equal to the width W3 of the third sub-body 611, whereby the second circuit board body 61 can be inserted into the second insertion hole through the top surface of the second insertion portion 315.

[0017] Of course, in some embodiments, the transformer may not include the first insertion portion 314 and the second insertion portion 315. The first intermediate column 214 of the first magnetic body 21 only sequentially penetrates through the first circuit board through-hole 52 and the bobbin through-hole 32, so that the first circuit board 5 is installed between the first main surface 211 of the first magnetic body 21 and the bobbin body 31. Similarly, the second intermediate column 224 of the second magnetic body 22 only sequentially penetrates through the second circuit board through-hole 62 and the bobbin through-hole 32, so that the second circuit board 6 can be installed between the second main surface 221 of the second magnetic body 22 and the bobbin body 31.

[0018] As described above, the inner first coil of the transformer of the present invention is located between the outer first coil and the outer peripheral surface of the bobbin body, and the second coil is located between the inner first coil and the outer first coil. That is, since the outer first coil, the second coil, and the inner first coil are sequentially provided in the stacking direction, while each coil of the conventional transformer is irregularly wound around the core, the inner first coil, the outer first coil, and the second coil of the transformer of the present invention are arranged as described above, so that the leakage inductance of the transformer can be significantly reduced. At the same time, since the arrangement of the inner first coil, the outer first coil, and the second coil in the transformer is sequential and difficult to be wound alternately, the transformer of the present invention has the advantages of simple manufacturing process, easy realization of automation, stable product quality and dimensions, high product commonality, and small volume.

Explanation of Reference Numerals

[0019] 1: Transformer 2: Core 21: First magnetic body 211: First main surface 212: First side surface 213: Second side surface 214: First intermediate column 22: Second magnetic body 221: Second main surface 222: Third side surface 223: Fourth side surface 224: Second intermediate column 3: Bobbin 31: Bobbin body 311: First wall surface 312: Second wall surface 313: Outer peripheral surface 314: First insertion part 315: Second insertion part 316: First concave part 317: First insertion hole 318: Second concave part 32: Spool frame through hole 33: Coil winding space part 41: First coil 42: Second coil 5: First circuit board 51: First circuit board body 511: First sub - body 512: Second sub - body 52: First circuit board through hole 6: Second circuit board 61: Second circuit board body 611: Third sub - body 612: Fourth sub - body 62: Second circuit board through hole W1, W2, W3, W4: Width

Claims

1. A core including a first magnetic body and a second magnetic body; a reel including a reel body, a reel through hole, and a winding space portion, the reel through hole penetrating both opposing faces of the reel body, and the winding space portion being formed on an outer peripheral surface of the reel body; an outer first coil wound in the winding space; an inner first coil located between the outer first coil and the outer circumferential surface of the bobbin body; a second coil wound in the winding space and positioned between the inner first coil and the outer first coil; a first circuit board having a circuit board through hole connected to the bobbin through hole; A second circuit board; Equipped with a portion of the core passes through the circuit board through hole and the bobbin through hole, and a shortest distance between each of the inner first coil and the outer first coil and the first circuit board, a shortest distance between each of the inner first coil and the outer first coil and the second circuit board, a shortest distance between the second coil and the first circuit board, and a shortest distance between the second coil and the second circuit board.

2. the second circuit board has a second circuit board through hole and is located between the second magnetic body and the winding frame body; the first circuit board is located between the first magnetic body and the spool body, and has a first circuit board through hole; 2. The transformer according to claim 1, wherein the first circuit board through hole, the second circuit board through hole, and the reel through hole are in communication with one another, and a portion of the core passes through the first circuit board through hole, the second circuit board through hole, and the reel through hole.

3. the first magnetic body includes a first main surface, a first side surface, a second side surface, and a first intermediate column, the first side surface and the second side surface are connected to opposite ends of the first main surface, and the first intermediate column is connected to the first main surface and is located between the first side surface and the second side surface; 3. The transformer according to claim 2, wherein the second magnetic body includes a second main surface, a third side surface, a fourth side surface, and a second intermediate column, the second main surface and the first main surface are disposed opposite to each other, the third side surface and the fourth side surface are connected to opposite ends of the second main surface, the third side surface is connected to the first side surface, the fourth side surface is connected to the second side surface, the second intermediate column is connected to the second main surface and is located between the third side surface and the fourth side surface, and the second intermediate column is connected to the first intermediate column, and the first intermediate column and the second intermediate column pass through the first circuit board through hole, the second circuit board through hole, and the winding frame through hole.

4. 3. The transformer according to claim 2, wherein the reel body has a first wall surface, a second wall surface, a first insertion portion, and a second insertion portion, the first wall surface and the second wall surface are disposed at opposite ends of the reel body, the outer circumferential surface of the reel body is located between the first wall surface and the second wall surface, the reel through hole penetrates the first wall surface and the second wall surface of the reel body, the first insertion portion is connected to one end of the first wall surface of the reel body, the first insertion portion is disposed offset from the reel through hole without covering the reel through hole, the first insertion portion has a first internal recessed portion provided with a first insertion hole, the second insertion portion is connected to one end of the second wall surface of the reel body, the second insertion portion is disposed offset from the reel through hole without covering the reel through hole, and the second insertion portion has a second internal recessed portion provided with a second insertion hole.

5. the first circuit board has a first circuit board body, the first circuit board through hole penetrates the first circuit board body, a portion of the first circuit board body is inserted into the first insertion hole, and the first circuit board is located between the spool body and a first main surface of the first magnetic body, 5. The transformer according to claim 4, wherein the second circuit board has a second circuit board body, the second circuit board through hole penetrates the second circuit board body, a portion of the second circuit board body is inserted into the second insertion hole, and the second circuit board is located between the bobbin body and the second main surface of the second magnetic body.

6. 2. The transformer of claim 1, wherein the outer and inner first coils are both part of a primary coil of the transformer, the second coil is part of a secondary coil of the transformer, the first circuit board is another part of the primary coil of the transformer, and the second circuit board is another part of the secondary coil of the transformer.

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