Separate circuit

Abstract

Provides isolated circuits that meet high voltage resistance and safety regulation standards. [Solution] A separated circuit 300 includes a power factor improvement circuit 310 and a resonant conversion circuit 320. The resonant conversion circuit includes a primary circuit 321, a resonant circuit 322, and a secondary circuit 323. The resonant circuit includes a resonant inductance Lr, a resonant capacitor Cr, and a transformer T. The transformer includes a primary winding Np and a secondary winding Ns. The primary winding and / or the secondary winding includes a winding, and the winding includes a conductor and an insulating layer that covers the conductor. After the side of the insulating layer parallel to the X-axis direction is fixed on the conductor arranged parallel to the X-axis direction, the insulating layer is wound along the Y-axis direction perpendicular to the X-axis direction to cover the conductor so that the number of insulating layers of the conductor is at least three. The withstand voltage between the input terminal and the output terminal of the separated circuit is 4000VAC to 5000VAC.

Description

[Technical field]

[0001] The present invention relates to the technical field of power electronics, and in particular to an isolation circuit. [Background technology]

[0002] In general, the inductance of a switching power supply can be increased by adding an external inductance to the transformer. This improves the electrical performance of the transformer, such as load adaptability and stability, and allows the transformer to operate more effectively in various environments. Increasing the inductance reduces the short-circuit current of the transformer and reduces the current loss in the transformer windings (coils), improving the efficiency of the transformer and reducing energy loss.

[0003] In the transformer structure, instead of providing an external inductance component, a grooved spacer structure may be provided between the primary winding and the secondary winding to increase the distance between the primary winding and the secondary winding. However, providing the grooved spacer structure increases the overall height of the transformer, which is problematic in that it does not meet the requirement for a low overall height of a thin transformer.

[0004] In addition, in order to meet the safety regulations and insulation requirements, most of the transformers of existing switching power supplies use triple-insulated wire as a winding. Although this method meets the requirements of safety regulations, the material cost of triple-insulated wire is relatively high, so the reduction of production costs cannot be realized. In addition, triple-insulated wire also has the problem of high hardness, which cannot be applied to winding. In addition, the volume of the transformer is likely to be large, which is not helpful in improving the power density of the transformer. Because triple-insulated wire is used for the winding, the volume is large, the primary winding and secondary winding of the transformer are close to each other, and the withstand voltage between the input and output ends of the circuit is low, so the requirements for high-voltage applications cannot be met. Another type of winding in which the insulator is coated in a spiral shape also has the above problems.

[0005] In view of this, the present invention proposes a separation circuit to solve the above existing problems. Summary of the Invention

[0006] In order to solve the above problems, the object of the present invention is to provide a separated circuit comprising a power factor correction circuit and a resonant conversion circuit connected in series in this order, the resonant conversion circuit comprising a primary circuit, a resonant circuit and a secondary circuit connected in series in this order, the primary circuit being electrically connected to the power factor correction circuit, the resonant circuit comprising a resonant inductance, a resonant capacitor and a transformer, the transformer comprising a primary winding and a secondary winding, the resonant inductance, the resonant capacitor and the primary winding being connected in series, the secondary circuit being electrically connected to the secondary winding, the primary winding and / or the secondary winding comprising a winding, the winding comprising a conductor and an insulating layer covering the conductor, the insulating layer being wound along a Y-axis direction perpendicular to the X-axis direction to cover the conductor so that the number of insulating layers covering the conductor is at least three, and the withstand voltage between the input terminal and the output terminal of the separated circuit is 4000VAC to 5000VAC.

[0007] According to one embodiment of the present invention, a power factor correction circuit includes a rectifier circuit and a boost circuit connected in series in sequence, and the boost circuit includes an energy storage inductor, a first switch, a diode and a first output capacitor, a first end of the energy storage inductor is electrically connected to the rectifier circuit, a first power terminal of the first switch is electrically connected to a second end of the energy storage inductor, a second power terminal of the first switch is electrically connected to a ground terminal, an anode terminal of the diode is electrically connected to the first power terminal of the first switch, a first end of the first output capacitor is electrically connected to a cathode terminal of the diode, and a second end of the first output capacitor is electrically connected to the ground terminal.

[0008] According to one embodiment of the present invention, the primary circuit includes an inverter circuit, the inverter circuit is electrically connected to the boost circuit, the inverter circuit includes a second switch and a third switch, the third switch is connected in series with the second switch between the cathode terminal of the diode and a ground terminal, the secondary circuit includes a fourth switch, a fifth switch and a second output capacitor, a first power terminal of the fourth switch is electrically connected to a first end of the secondary winding, a second power terminal of the fourth switch is electrically connected to an output negative terminal of the separated circuit, a first power terminal of the fifth switch is electrically connected to a second end of the secondary winding, a second power terminal of the fifth switch is electrically connected to the output negative terminal of the separated circuit, the second output capacitor is electrically connected between the output positive terminal and the output negative terminal of the separated circuit, the secondary winding has a center tap terminal, the center tap terminal is electrically connected to the output positive terminal of the separated circuit.

[0009] According to one embodiment of the present invention, the winding comprises a plurality of conductor wires, which are twisted together in a spiral at least 33 times within a length of 1 meter.

[0010] According to one embodiment of the present invention, each conductor in the plurality of conductors comprises a core wire and a coating layer, the core wire has a first wire diameter, the twisted conductors have a second wire diameter, and the winding has a third wire diameter, the third wire diameter being smaller than a total wire diameter when each conductor in the plurality of conductors is coated with at least three insulating layers, and the third wire diameter is smaller than the total wire diameter when the conductors are coated with at least three insulating layers.

[0011] According to one embodiment of the present invention, the number of the plurality of conductive wires is 33 or more, and the second wire diameter is at least 0.55 mm.

[0012] According to one embodiment of the present invention, the insulating layer includes an insulating tape.

[0013] According to one embodiment of the present invention, there is a spacing distance between the primary winding and the secondary winding.

[0014] According to one embodiment of the present invention, an interlayer insulating film is provided between the spacing distances.

[0015] According to one embodiment of the present invention, the resonant inductance is comprised of a leakage inductance formed by a spacing distance or an interlayer dielectric.

[0016] According to one embodiment of the invention, when the resonant inductance is an external inductance, the resonant inductance comprises a winding. Effect of the Invention

[0017] The separated circuit of the present invention has the advantages of being easy to process by automation, being coated with at least three insulating layers, and having a smaller final wire diameter than the conventional triple-insulated windings, and meeting high voltage resistance and safety regulations. In addition, the use of a winding with a smaller final wire diameter allows the overall height of the transformer to be kept low, the volume of the winding set to be reduced, and the space between the winding sets to be expanded, and the leakage inductance to be increased. [Brief description of the drawings]

[0018] [Figure 1] FIG. 2 is a structural conceptual diagram of a first embodiment of a winding according to the present invention; [Diagram 2] FIG. 2 is a side view of FIG. [Diagram 3] FIG. 4 is a structural conceptual diagram of a second embodiment of a winding according to the present invention. [Figure 4] FIG. 4 is a side view of FIG. [Diagram 5] 2 is a flowchart of a method for manufacturing the winding in FIG. 1. [Figure 6] 6 is a flowchart of a sub-step of step S12 in FIG. 5. [Figure 7] 4 is a flowchart of a method for manufacturing the winding in FIG. 3. [Figure 8] FIG. 11 is a structural conceptual diagram of a third embodiment of a winding according to the present invention. [Figure 9] FIG. 2 is a cross-sectional view of the winding of FIG. [Figure 10] FIG. 9 is a cross-sectional view of the winding of FIG. 8. [Figure 11] FIG. 10 is a cross-sectional view of a single conductor in a winding having multiple conductors in a fourth embodiment of the winding of the present invention. [Figure 12] FIG. 2 is a side view of a plurality of conductor wires twisted together in a helical configuration. [Figure 13] 13 is a side view of a fourth embodiment of a winding according to the present invention, the winding having an insulating layer covering the twisted conductors of FIG. 12. [Figure 14] FIG. 14 is a cross-sectional view of the winding of FIG. 13. [Figure 15A] 1 is a diagram showing a winding jig, a wire winding jig, and a winding process of the present invention. [Figure 15B] 1 is a diagram showing a winding jig, a wire winding jig, and a winding process of the present invention. [Figure 15C] FIG. 1 is a conceptual diagram of the structure of a conductor coated with an insulating layer. [Figure 15D] FIG. 2 is a conceptual structural diagram showing the state after both ends of a conductor covered with an insulating layer have been cut. [Figure 16] FIG. 2 is a structural conceptual diagram showing the state in which the twisting jig of the present invention performs twisting work. [Figure 17] 2 is a structural schematic diagram of the exposed end of the twisted conductor of the present invention; FIG. [Figure 18] FIG. 2 is a structural conceptual diagram showing the state in which the soldering work of the present invention is performed. [Figure 19A] FIG. 2 is a schematic diagram of the winding structure after the soldering work of the present invention is completed. [Figure 19B] FIG. 2 is a schematic diagram of the structure of the present invention after the winding is bent after the soldering work is completed. [Figure 20] 1 is an exploded view of a thin transformer according to the present invention; [Figure 21] 1 is an exploded view of a thin transformer according to the present invention; [Figure 22] FIG. 2 is an exploded view of a winding former according to the present invention; [Figure 23A] 2 is a cross-sectional view taken along the line T1-T1' in one embodiment of a thin transformer according to the present invention. FIG. [Figure 23B] 2 is a cross-sectional view taken along the line T2-T2' of a thin transformer according to an embodiment of the present invention. FIG. [Figure 24A] 10 is a cross-sectional view of a thin transformer according to another embodiment of the present invention taken along the line T1-T1'. FIG. [Figure 24B] FIG. 2 is a cross-sectional view taken along the line T2-T2′ of another embodiment of a thin transformer according to the present invention. [Diagram 25] FIG. 2 is a schematic diagram of an embodiment of a separation circuit according to the present invention; [Figure 26] FIG. 4 is a schematic diagram of another embodiment of an isolated circuit according to the present invention; [Figure 27] 2 is a flow chart of a method for testing the withstand voltage of an isolated circuit according to the present invention. [Explanation of symbols]

[0019] 11, 21, 31, 41: Conductor 12, 22: Insulation structure 121, 321: First insulating layer 122: Second insulating layer 1221, 2221: 1st fixed part 1222, 2222: overlapping part 1223, 2223: Second fixed part 123: First colloid layer 124: Second colloid layer 125: Third colloid layer 100: Winding jig 101: Fixed part 110: Wire winding jig 111: First member 112: Second member 200: Twisting jig 210: First twisting section 220: Second twist section 230: Recess 221: First insulating tape 222: Second insulating tape 300, 300a: Separate circuit 310: Power factor correction circuit 311: Rectifier circuit 312: Boost circuit 320: Resonant conversion circuit 321: Primary circuit 322: Resonant circuit 323: Secondary circuit 310a: Primary circuit 311a: Rectifier circuit 312a: RCD absorption circuit 320a: Secondary circuit 411: Core wire 412: Coating layer 42: Insulating layer 5, 5a: Thin transformer 50, 50a: Winding frame 51: 1st plate 52:Second plate 53, 53a: Hollow pillar 60, 60a: Iron core 61: First core 611:1st Base 612: First stem 62: Second core 621:Second base 622: Second stem 70, 70a: 1st winding set 80, 80a: 2nd winding set 90, 90a: Spacing distance A: Conductor A1: 1st exposed part A2: Covered part A3: 2nd exposed part Aa: 1st exposed end Ab: 2nd exposed end Aa1: First solder part Ab1: Second solder part B1: 1st adhesive layer B2: Second adhesive layer C1: Bleed capacitor Cf: First output capacitor Cfa: Filter capacitor Co: Second output capacitor Coa: Output capacitor Cr: Resonant capacitor d1, d2, d3, d4: Diodes D1: First wire diameter D2: Second wire diameter D3: Third wire diameter E: Insulating layer E1: Edge F: Gap G: Ground terminal I1: First insulating substrate layer I2: Second insulating substrate layer Ia: Interlayer insulating film Lf: energy storage inductor Lr: Resonant inductance Np: Primary winding Ns: Secondary winding Q1: First switch Q1a: Switch Q2: Second switch Q3: 3rd switch Q4: 4th switch Q5: 5th switch R: Resistance S11, S12, S13, S121, S122, S21, S22, S23, S100, S200: Step T: Trans T1, T1', T2, T2': Section lines V: Career W11, W21: 1st width W12, W22: Second width X, Y, Z: Axes DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Some exemplary embodiments of the features and advantages of the present invention are 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 that the detailed description and drawings are for illustrative purposes only and are not intended to limit the present invention.

[0021] The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments. The following embodiments are implemented on the premise of the technical solutions of the present invention, and the following embodiments and operations are presented, but the scope of the present invention is not limited to the following embodiments.

[0022] Please refer to Figures 1 and 2. Figure 1 is a structural conceptual diagram of a first embodiment of the winding of the present invention. Figure 2 is a side view of Figure 1. As shown in Figures 1 and 2, the winding of the present invention includes a conductor 11 and an insulating structure 12. The conductor 11 is a basically insulated solid wire or a basically insulated twisted wire (a wire twisted together with a plurality of single wires), etc. The insulating structure 12 covers the conductor 11 (surrounds and covers the outside of the conductor 11), and the insulating structure 12 includes a first insulating layer 121 and a second insulating layer 122. The first insulating layer 121 has a first width W11. The second insulating layer 122 has a second width W12. The second insulating layer 122 has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction. The first insulating layer 121 is disposed on the second insulating layer 122 along a direction parallel to the X-axis direction. The first width W11 is smaller than the second width W12. The conductor 11 is disposed on the second insulating layer 122 along a direction parallel to the X-axis direction and is not covered by the first insulating layer 121. The first insulating layer 121 and the second insulating layer 122 cover the conductor 11 along the Y-axis direction (surround and cover the outside of the conductor 11). In some embodiments of the present invention, in order to meet safety requirements, the first insulating layer 121 and the second insulating layer 122 cover the conductor 11 such that the number of insulating layers of the winding is at least three. By controlling the first width W11 and / or the second width W2 and the position of the first insulating layer 121 on the second insulating layer 122, the number of insulating layers of the winding can be controlled, and the processing method is simple and the cost is lower than that of a three-layer insulated wire.

[0023] Further, the first insulating layer 121 is attached to the second insulating layer 122. The second insulating layer 122 is divided into a first fixing portion 1221, an overlapping portion 1222, and a second fixing portion 1223 in sequence along the Y-axis direction. The conductor 11 is provided on the second fixing portion 1223 so as to be parallel to the X-axis direction. The width of the first fixing portion 1221 and / or the second fixing portion 1223 is equal to or greater than the periphery of the conductor 11. The width of the overlapping portion 1222 is equal to or greater than the periphery of the conductor 11. In some embodiments of the present invention, the widths of the first fixing portion 1221, the second fixing portion 1223, and the overlapping portion 1222 may be set equal to the periphery of the conductor 11. In this case, the number of insulating layers of the winding is just three, which leads to material saving and cost reduction, and makes it easy to realize automated processing. Note that the effect of the thickness of the insulating layer is not considered (neglected) here.

[0024] Furthermore, the insulating structure 12 includes a first colloid layer 123 and a second colloid layer 124. The first colloid layer 123 is disposed on the first fixing portion 1221 and / or the second fixing portion 1223, and the conductive wire 11 is disposed on the first colloid layer 123. The first colloid layer 123 is used to more firmly fix the conductive wire 11 on the second insulating layer 122. The second colloid layer 124 is disposed between the overlapping portion 1222 and the first insulating layer 121, and is used to bond the first insulating layer 121 and the second insulating layer 122. The conductive wire 11 is coated from the second fixing portion 1223 on which the conductive wire 11 is disposed until it is bonded to the first fixing portion 1221. In some embodiments of the present invention, the thicknesses of the first colloid layer 123 and the second colloid layer 124 can be controlled to be constant, as shown in FIG. 2.

[0025] In addition, in other embodiments, the conductor 11 is arranged on the first fixed portion 1221 along a direction parallel to the X-axis direction, and the conductor 11 is covered from the first fixed portion 1221 on which the conductor 11 is arranged until it is bonded to the second fixed portion 1223.

[0026] The winding of the present invention can also adopt a method of directly connecting the conductive wire 11 and the first insulating layer 121 during the winding process, which can make the insulating structure 12 easier to smoothly wind (wrap) the conductive wire 11 and ensure that the surface of the wire after processing is smooth and firmly fixed. However, the present invention is not limited to this.

[0027] The insulating structure 12 further includes a third colloid layer 125 disposed on the first insulating layer 121, which can better fix the conductive wire 11 during the winding process compared to the above-mentioned manner of directly connecting the conductive wire 11 to the first insulating layer 121.

[0028] Please refer to Figures 3 and 4. Figure 3 is a structural conceptual diagram of a second embodiment of the winding of the present invention. Figure 4 is a side view of Figure 3. As shown in Figures 3 and 4, the winding of the present invention includes a conductor 21 and an insulating structure 22. The insulating structure 22 winds and covers the conductor 21. The conductor 21 is a basically insulated solid wire or a basically insulated twisted wire (a wire twisted together with a plurality of single wires), etc. The insulating structure 22 includes a first insulating tape 221 and a second insulating tape 222. The first insulating tape 221 has a first width W21, the second insulating tape 222 has a second width W22, and the second insulating tape 222 has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction. The first insulating tape 221 is attached on the second insulating tape 222 along a direction parallel to the X-axis direction. The first width W21 is smaller than the second width W22. The conductive wire 21 is disposed on the second insulating tape 22 along a direction parallel to the X-axis direction and is not covered by the first insulating tape 221. The first insulating tape 221 and the second insulating tape 222 are wound around and covered the conductive wire 21 along the Y-axis direction. In some embodiments of the present invention, the first insulating tape 221 and the second insulating tape 222 are wound around and covered the conductive wire 21 such that the number of insulating layers of the winding is three to meet safety requirements.

[0029] The first insulating tape 221 includes a first adhesive layer B1 and a first insulating base layer I1 that are disposed opposite each other. The second insulating tape 222 includes a second adhesive layer B2 and a second insulating base layer I2 that are disposed opposite each other. After the first adhesive layer B1 and the second adhesive layer B2 are bonded together, that is, after the first insulating tape 221 is attached to the second insulating tape 222, the insulating base layer I2 of the second insulating tape 222 is divided into three parts, a first fixing portion 2221, an overlapping portion 2222, and a second fixing portion 2223, along the Y-axis direction. In other words, the first insulating base layer I1 and the second insulating base layer I2 are the first insulating layer 121 and the second insulating layer 122, respectively.

[0030] The conductor 21 is disposed on the second fixing portion 2223 along a direction parallel to the X-axis direction. Since the second adhesive layer B2 is provided between the second fixing portion 2223 and the conductor 21, the conductor 21 can be firmly fixed on the second insulating base material layer I2 before winding begins. When the conductor 21 is wound and covered, if the connection portion between the first insulating tape 221 and the winding is the insulating base material layer I1, the contact surface becomes smooth and smooth, so that the conductor 21 can be smoothly and easily wound and can be wound reliably. This ensures that the surface of the wire after processing is smooth and dense. In addition, since the first fixing portion 2221 similarly has the adhesive layer B2, it is easy to adhere to the second insulating base material layer I2, and finally, winding is completed to obtain a winding with an insulating layer. In addition, the texture of the insulating tape is relatively soft, and when used in a winding set of a transformer or other magnetic components, the gap between the windings can be made smaller than that of a three-layer insulated wire, the volume of the magnetic components is reduced, and the power density can be further increased. In addition, in other embodiments, the conductive wire 21 may be arranged on the first fixed portion 2221 along the X-axis direction, starting from the first fixed portion 2221 on which the conductive wire 21 is provided, so as to cover the conductive wire 21 until it is bonded to the second fixed portion 2223.

[0031] In another embodiment of the present invention, by attaching the first insulating base layer I1 and the second adhesive layer B2, the insulating base layer I2 of the second insulating tape 222 is divided into a first fixing portion 2221, an overlapping portion 2222, and a second fixing portion 2223, respectively.

[0032] The width of the first fixing portion 2221 and / or the second fixing portion 2223 may be equal to or greater than the periphery of the conductor 21, and the width of the overlapping portion 2222 may be equal to or greater than the periphery of the conductor 21. In some embodiments of the present invention, the widths of the first fixing portion 2221, the second fixing portion 2223 and the overlapping portion 2222 may all be set equal to the periphery of the conductor 11. This reduces the number of insulating layers of the winding to just three, which is favorable for saving materials and reducing costs, and also facilitates automated processing. Note that the effect of the thickness of the insulating tape is ignored here.

[0033] Please refer to Figures 5 and 6. Figure 5 is a flow chart of the method for manufacturing the winding of Figure 1. Figure 6 is a flow chart of the sub-steps of step S12 of Figure 5. As shown in Figures 5 and 6, the method for manufacturing the winding of the present invention includes the following steps:

[0034] (Step S11): A first insulating layer having a first width is disposed on the second insulating layer along the X-axis direction of the second insulating layer having a second width, the first width being smaller than the second width. In one embodiment of the present invention, after the first insulating layer is disposed on the second insulating layer, the second insulating layer is divided into a first fixing portion, an overlapping portion, and a second fixing portion along the Y-axis direction, in order. The width of the first fixing portion and / or the second fixing portion may be equal to or greater than the periphery of the conductor, and the width of the overlapping portion may be equal to or greater than the periphery of the conductor. In some embodiments of the present invention, the widths of the first fixing portion, the second fixing portion, and the overlapping portion are all set equal to the periphery of the conductor. This makes the number of insulating layers of the winding exactly three, which is favorable for saving materials and reducing costs, and is also easy to realize automated processing. In another embodiment of the present invention, after the first insulating layer is disposed on the second insulating layer, the second insulating layer is divided into two parts, the first fixing portion and the overlapping portion, along the Y-axis direction, but the present invention is not limited thereto.

[0035] (Step S12): A step of placing a conductor on the second insulating layer in a direction parallel to the X-axis direction and in a portion not covered by the first insulating layer. In one embodiment of the present invention, after the first insulating layer is placed on the second insulating layer, the second insulating layer is divided into a first fixing portion, an overlapping portion, and a second fixing portion in the Y-axis direction, in that order. The conductor is placed on the first fixing portion or the second fixing portion, and the conductor may be a basically insulated solid wire or a basically insulated stranded wire, etc.

[0036] (Step S13): A step of surrounding and covering the outside of the conductor with the first insulating layer and the second insulating layer along the Y-axis direction perpendicular to the X-axis direction, covering the conductor from the first fixing part where the conductor is installed to the second fixing part, or covering the conductor from the second fixing part where the conductor is installed to the first fixing part.

[0037] Furthermore, step S12 further includes the following steps.

[0038] (Step S121): A step of placing a first colloid layer on the first fixing part and / or the second fixing part.

[0039] (Step S122): A step of placing a conductive wire on the first colloid layer.

[0040] Further, in step S11, a second colloid layer is disposed between the overlapping portion and the first insulating layer, and / or in step S11, a third colloid layer is disposed on the first insulating layer.

[0041] In some embodiments of the present invention, a first insulating layer and a second insulating layer are wound around the conductor wire, and the number of insulating layers in the winding is at least three.

[0042] Please refer to Fig. 7. Fig. 7 is a flow chart of a method for manufacturing the winding of Fig. 3. As shown in Fig. 7, the method for manufacturing the winding of the present invention includes the following steps:

[0043] (Step S21): A step of placing a first insulating tape having a first width on a second insulating tape along an X-axis direction of the second insulating tape having a second width, the first width being smaller than the second width.

[0044] (Step S22): A step of placing a conductor on the second insulating tape along a direction parallel to the X-axis direction and in a portion not covered by the first insulating tape, the conductor being an essentially insulated solid wire or an essentially insulated stranded wire.

[0045] (Step S23): A step of wrapping the first insulating tape and the second insulating tape around the conductor wire along the Y-axis direction perpendicular to the X-axis direction.

[0046] Furthermore, in step S21, the first insulating tape includes a first adhesive layer and a first insulating base material layer arranged opposite to each other, and the second insulating tape includes a second adhesive layer and a second insulating base material layer arranged opposite to each other, and in step S21, the first adhesive layer and the second adhesive layer are attached. That is, after the first insulating tape is attached to the second insulating tape, the insulating base material layer of the second insulating tape is divided into three parts, a first fixing part, an overlapping part, and a second fixing part, along the Y-axis direction. In other words, the first insulating base material layer and the second insulating base material layer are the first insulating layer and the second insulating layer, respectively.

[0047] Furthermore, in step S22, the conductor is placed on the second fixing part along a direction parallel to the X-axis direction. Since there is a second adhesive layer between the second fixing part and the conductor, the conductor can be fixed to the second insulating layer before being wound. In step S23, the conductor is covered by wrapping from the second fixing part where the conductor is placed to the first fixing part. The conductor is covered by wrapping the first insulating tape and the second insulating tape. When covering the conductor, the part where the first insulating tape and the winding contact is the insulating base material layer and is a smooth flat surface, so that the conductor can be easily wound smoothly, and the surface of the processed electric wire is smooth and dense without wrinkles. In addition, since there is an adhesive layer on the first fixing part, adhesion to the second insulating base material layer is easier, and finally, the winding is completed to obtain a winding including an insulating layer.

[0048] In another embodiment, the conductor is placed on the first fixed portion along a direction parallel to the X-axis direction, and the conductor is wrapped around and coated from the first fixed portion on which the conductor is placed until it is bonded to the second fixed portion.

[0049] In another embodiment of the present invention, a first insulating base layer and a second adhesive layer are attached, and the insulating base layer of the second insulating tape is divided into a first fixing portion, an overlapping portion, and a second fixing portion, in order.

[0050] In some embodiments of the present invention, the width of the first fixing part and / or the second fixing part may be designed to be equal to or larger than the wire diameter of the conductor, and the width of the overlapping part may be designed to be equal to or larger than the wire diameter of the conductor. If the widths of the first fixing part, the second fixing part and the overlapping part are all equal to the wire diameter of the conductor, the number of insulation layers of the winding is just three, which is favorable for saving materials and reducing costs, and can be easily realized in automated processing.

[0051] Please refer to Figure 8. Figure 8 is a structural conceptual diagram of a third embodiment of the winding of the present invention. As shown in Figure 8, the winding of the present invention includes a conductor 31 and a first insulating layer 321, the conductor 31 is a basically insulated solid wire or a basically insulated stranded wire, the first insulating layer 321 has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction, the conductor 31 is disposed on the first insulating layer 321 along a direction parallel to the X-axis direction, and the first insulating layer 321 is wound along the Y-axis direction to cover the conductor 31.

[0052] By setting the width of the first insulating layer 321, the number of insulating layers of the winding after the first insulating layer 321 is wound around the conductive wire 31 can be at least three. In some embodiments of the present invention, the first insulating layer 321 can be an insulating base layer of an insulating tape, the conductive wire 31 is disposed on the first insulating layer 321 along a direction parallel to the X-axis direction, and an adhesive layer of the insulating tape is located between the conductive wire 31 and the first insulating layer 321.

[0053] Please refer to Figures 1 and 9. Figure 9 is a cross-sectional view of the winding in Figure 1. As shown in Figure 9, a first insulating layer 121 and a second insulating layer 122 are wound around and cover the conductive wire 11. The number of insulating layers of the winding is at least three.

[0054] Please refer to Figures 8 and 10. Figure 10 is a cross-sectional view of the winding in Figure 8. As shown in Figure 10, a first insulating layer 321 wraps around and covers the conductive wire 31. The number of insulating layers of the winding is at least three.

[0055] The present invention provides a winding set of a magnetic element, the winding set of the magnetic element comprising a winding as shown in FIG. 1, FIG. 3 or FIG. 8, i.e., the winding set is wound with the winding as described above.

[0056] Please refer to Figures 11-14. In another embodiment, the present invention discloses a winding, which includes a plurality of conductive wires 41 and an insulating layer 42. The conductive wires 41 are any one of the conductive wires 11, 21, and 31 described above, and the insulating layer 42 is any one of the insulating structures 12, 22, and insulating layer 321 described above.

[0057] As shown in Fig. 11, each conductor 41 includes a core 411 and a coating layer 412. The core 411 is made of a copper wire and has a first wire diameter D1 of 0.2 mm or less, which allows the core 411 to have better flexibility. The coating layer 412 has a thickness of 0.1 mm or less, preferably 0.02 mm to 0.03 mm, and the elongation of the coating layer 412 is 15% or more, which allows the conductor 41 formed by covering the core 411 with the coating layer 412 to be easily bent. Furthermore, the withstand voltage of the coating layer 412 is 1 kV or more, so that the conductor 41 has better insulation properties.

[0058] The multiple conductors 41 are twisted spirally close to each other, and as shown in FIG. 12, the multiple conductors 41 are combined so as to be spirally twisted at least 33 times within a length of 1 meter. In other words, the twisted multiple conductors 41 are twisted 360° in a clockwise or counterclockwise direction until they are spirally twisted at least 33 times within a length of 1 meter. The number of times that the multiple conductors 41 are spirally twisted is in the range of 33 to 85 times within a length of 1 meter. Note that FIG. 12 shows an actual winding situation, which is only for the purpose of explanation.

[0059] After being twisted into a spiral, the multiple conductors 41 approach each other due to a force, and the distance between adjacent conductors 41 is less than 0.1 mm. In addition, after being twisted into a spiral, the multiple conductors 41 form a circle with a second wire diameter D2 in a cross section perpendicular to the longitudinal direction, where D2≦C×√N×D1, where C is a constant for the number of twists, and N is the number of conductors 41. In some embodiments, for example, when the multiple conductors 41 are twisted into a spiral 33 times within a length of 1 meter, C is 1.115, and the value of C is inversely proportional to the number of spiral twists of the bundled conductors.

[0060] After twisting multiple conductors 41 into a spiral shape, an insulating layer 42 is wound around the outside of the conductors 41 as shown in FIG. 13. The insulating layer 42 is continuously wound around the outside of the conductors 41 until the number of insulating layers covering the conductors 41 reaches three.

[0061] The insulating layer 42 is wound around the outside of the conductor 41, and the distance between each conductor 41 and the insulating layer 42 on the circumference of the circle formed by twisting the multiple conductors 41 together is less than 0.1 mm. Furthermore, between the multiple insulating layers 42 covering the conductor 41, adjacent insulating layers 42 overlap smoothly and densely without wrinkles or gaps. The winding formed by winding the multiple conductors 41 with the insulating layer 42 has a third wire diameter D3, which is smaller than the total wire diameter of at least three layers of each conductor 41 formed by covering the multiple conductors 41 with the insulating layer 42. That is, it is smaller than the wire diameter of a known three-layer insulated wire. At the same time, the third wire diameter D3 is smaller than the total wire diameter of at least three layers formed by covering the multiple conductors 41 with the insulating layer 42 in a spiral shape. In some embodiments of the present invention, the thickness of the insulating layer 42 is 0.1 mm or less. The total thickness of the multiple insulating layers 42 covering the multiple conductors 41 is the product of the thickness of the insulating layers 42 and the number of layers covering the conductors 41 .

[0062] Furthermore, as shown in the table below, taking the example of a single conductor 41 having a wire diameter of about 0.1 mm, the second wire diameter D2 after the multiple conductors 41 are twisted together in a spiral shape is about 0.55 to 0.58 mm. The final wire diameter (i.e., the third wire diameter D3) of the winding formed by continuously winding the insulating layer 42 of the present invention is smaller than the wire diameter of a known three-layer insulated wire and the wire diameter of the insulating layer 42 helically covering the conductor 41. In other words, when the number of conductors 41 is 33 or more, the winding formed by the manufacturing method of the present invention can have a final wire diameter smaller than that of the prior art. JPEG0003250014000002.jpg61121

[0063] More specifically, the present invention forms a winding with an insulating layer / insulation structure by winding the conductor so that the insulating layer has at least three layers, thereby effectively increasing the thickness of the insulating layer outside the conductor while also achieving the effect of reducing the final wire diameter of the winding. When the winding is wound on the winding bobbin, the reduced wire diameter is favorable for reducing the volume of the entire winding set, increasing the distance between different winding sets, and further increasing the leakage inductance, reducing the external inductance, and even completely replacing the external inductance.

[0064] In addition, the present invention can achieve the effect of further improving the withstand voltage value of the winding by coating the core wire with a coating layer to form a single stranded wire, and then coating at least three insulating layers on the outer surface of the stranded single stranded wire to form a winding. For example, the thickness of the outer coating film of the known triple-layered insulated wire is 0.09 mm, and the withstand voltage value is about 3100 VAC, while the thickness of the insulating layer of the winding of the present invention is about 0.15 mm, and the withstand voltage value reaches about 5000 VAC. Experimental results show that the winding of the present invention can withstand an arc current of 7.7 mA for 60 seconds, which meets the safety regulations of IEC65960 and IEC60065. Therefore, it can be said that the winding proposed by the present invention greatly improves the shortcomings of the known triple-layered insulated wire.

[0065] In practical implementation, a winding jig can be further used to assist in covering the conductor with an insulating layer / structure. As shown in Fig. 15A to Fig. 15D, the winding jig 100 includes two fixing parts 101 for fixing both ends of the conductor A, the two fixing parts 101 are arranged along the X-axis direction, and the conductor A fixed thereon can be installed along the X-axis direction. Here, the conductor A is the above-mentioned twisted multiple strands (e.g., the multi-stranded wire 41 twisted at least 33 times within one meter).

[0066] The insulating layer E has an X-axis direction and a Y-axis direction perpendicular to the X-axis direction, and the side E1 parallel to the X-axis direction is fixed on the conductor A so as to be parallel to the conductor A, and the insulating layer E is wound along the Y-axis direction to cover the conductor A, and the number of covering insulating layers is at least three. Note that the insulating layer E is the insulating structure 12, 22 or the insulating layer 321, 42 described above, but the present invention is not limited to the illustrated structure.

[0067] Furthermore, a wire winding jig 110 may be used to assist the process of winding the insulating layer E to cover the conductor A. The wire winding jig 110 includes a first member 111 and a second member 112 that is inclined relative to the first member 111, and forms an inclined space between the first member 111 and the second member 112 to accommodate the insulating layer E and the conductor A. For example, the angle between the first member 111 and the second member 112 may be about 90°, or the angle may be determined based on the diameter of the conductor A. During operation, first, the insulating layer E is fixed onto the conductor A via the side E1 to pre-coat the conductor A, then the conductor A and the insulating layer E are placed in the inclined space formed by the first member 111 and the second member 112, one of the first member 111 and the second member 112 provides the stress for fixing and attaching, while the other provides the function of guiding the insulating layer E, and the wire is rotated by the wire winding jig 110 to complete the covering (winding) operation of the insulating layer E. This allows the insulating layer E to be smoothly wound around the conductor A, and the surface of the processed electric wire becomes flat and in close contact.

[0068] After the covering of the insulating layer E is completed, for example, after covering the outside of the conductor A with at least three insulating layers, the conductor A placed on the winding jig 100 is divided along the X-axis direction into a first exposed portion A1, a covered portion A2, and a second exposed portion A3, as shown in FIG. 15C.

[0069] Thereafter, the first exposed portion A1 and the second exposed portion A3 are cut to form the first exposed end Aa and the second exposed end Ab, respectively, and the conductor after completion of coating is removed from the winding jig 100. After cutting, the conductor at the first exposed end Aa and the second exposed end Ab is in a dispersed state, as shown in FIG 15D.

[0070] Next, the first exposed end Aa and the second exposed end Ab are twisted and soldered to complete preparation for winding around the winding frame. Here, the twisting operations for the first exposed end Aa and the second exposed end Ab are similar, so only the exposed first exposed end Aa will be described.

[0071] In the twisting operation, the distributed strands are formed into a spiral strand (a conductor wire twisted in a spiral shape) as shown in Figs. 12 to 14, for example, a spiral strand twisted in a spiral shape at least 33 times within 1 meter. In one embodiment, the twisting operation is performed using a twisting tool. As shown in Fig. 16, the twisting tool 200 includes a first twisting section 210 and a second twisting section 220, and the first exposed end Aa to be twisted is disposed between the first twisting section 210 and the second twisting section 220, and the first twisting section 210 and the second twisting section 220 hold both sides of the first exposed end Aa and rotate them simultaneously to complete the twisting operation. In one embodiment, the first twisting section 210 and the second twisting section 220 each have a recess 230 (for example, an arc-shaped recess) along the vertical direction, and the recess forms a space to accommodate the exposed end to be twisted when facing each other. After the twisting operation is completed, a tapered shape (see FIG. 17) is formed at the end of the first exposed end Aa, and the conductors of the first exposed end Aa are close to each other (e.g., the distance between adjacent conductors is less than 0.1 mm). By performing the twisting operation in this manner, the wire diameter tolerance after twisting is completed is within + / - 0.18 mm.

[0072] Next, the first exposed end Aa and the second exposed end Ab, whose tips are twisted into a tapered shape, are soldered together. In one embodiment, the soldering is performed in the following manner. As shown in FIG. 18, the windings that have been twisted are arranged at intervals and sandwiched in a carrier V, and the two tapered ends to be soldered are exposed on both sides of the carrier V, and then the carrier V is moved, so that the windings can be soldered simultaneously. The soldering conditions can be changed according to actual needs, and the present invention is not limited thereto.

[0073] After the soldering operation is completed, the first exposed end Aa and the second exposed end Ab form the first solder portion Aa1 and the second solder portion Ab1, respectively, as pins of the winding to be wound around the winding frame. As shown in FIG. 19A and FIG. 19B, in the present invention, when the first exposed end Aa and the second exposed end Ab are covered in the soldering operation, the portion close to the covered portion A2 is re-covered with tin (i.e., a gap F is left between both ends of the covered portion A2 and the first solder portion Aa1 and the second solder portion Ab1). The gap F ensures a space for the solder portion to bend to form a pin when the completed winding is wound around the winding frame, and prevents the pin from becoming unbendable due to soldering and / or the covering of the insulating layer, and at the same time, the gap F can prevent the insulating tape from breaking when it is bent after being covered with the insulating tape. Here, the bending angle α is the angle between the solder portions Aa1, Ab1 of the winding and the covered portion A2. The gap F is approximately inversely proportional to the required pin bending angle α. That is, when the required pin bending angle α is small, the gap F needs to be made larger. The gap F is proportional to the wire diameter of the conductor A. That is, when the conductor wire diameter increases, the gap F needs to be made larger. In one embodiment, when the gap F is 0.5 mm to 3 mm, the bending angle α is 90° or more.

[0074] Next, the winding with both ends twisted and soldered is wound. Here, two windings are taken as an example, but the present invention is not limited thereto. One end of the winding (soldered end) is first placed on the winding frame. Marks are attached to distinguish different windings, and the corresponding winding operation is performed according to the type of transformer. After the winding is completed, the other end of the winding (soldered end) is placed on the winding frame again, and the winding is fixed with tape. It should be noted that both ends of the winding can be fixed on the same side or opposite sides of the winding frame without any restrictions according to different needs.

[0075] As described above, the process of forming a winding from a conductor wire and winding it around a winding frame in the present invention involves twisting multiple conductor wires together in a spiral at least 33 times within 1 meter to form a stranded conductor wire, coating the outside of the stranded conductor wire with at least three insulating layers, cutting both ends of the coating to form exposed ends, and then twisting and soldering the exposed ends to complete the preliminary preparation of the winding, after which the manufactured winding is wound around a winding frame and the soldered ends become pins to form a winding set. The winding of the present invention can also be applied to magnetic component structures such as transformers and inductors.

[0076] In some embodiments of the present invention, by adopting the winding of the present invention and further designing the transformer structure, the effect of reducing the overall height of the entire transformer can be achieved, and the inductance maintenance requirements of the switching power supply can also be realized.

[0077] 20, 21, and 22 are respectively a three-dimensional structure diagram of the thin transformer of the present invention, an exploded view of the thin transformer, and a three-dimensional structure diagram of the winding frame. The thin transformer 5 of the present invention includes a winding frame (bobbin) 50, a pair of iron cores 60, a first winding set 70, and a second winding set 80. The winding frame 50 includes a first plate body 51 and a hollow pillar 53 protruding from the first plate body 51. More specifically, the winding frame 50 has a second plate body 52 corresponding to the first plate body 51. A hollow pillar 53 is provided between the first plate body 51 and the second plate body 52.

[0078] The pair of cores 60 are disposed on opposite sides of the winding frame 50, and include a first core 61 and a second core 62. The first core 61 includes a first base 611 and a first stem 612 connected to the first base 611. The second core 62 includes a second base 621 and a second stem 622 connected to the second base 621. The first base 611 is attached to the first plate 51. The second base 621 is attached to the second plate 52. The hollow column 53 is provided so as to penetrate the first stem 612 and the second stem 622. Furthermore, the first winding set 70 (or primary winding) is disposed on the first plate 51, surrounding the hollow column 53, and is located between the pair of iron cores 60. The second winding set 80 (or secondary winding) is disposed on the first plate 51, surrounding the first winding set 70. There is a gap 90 between the second winding set 80 and the first winding set 70. In actual implementation, the gap 90 is 0.2 mm or more and 13.5 mm or less, but the present invention is not limited thereto. In actual implementation, the first winding set 70 and / or the second winding set 80 adopt a winding having the above-mentioned structure, which has characteristics such as a small wire diameter and easy to wind densely, and due to this structure, the thickness of the thin transformer 5 is thinner than 20 mm. More specifically, the high-voltage winding in the first winding set 70 or the second winding set 80 can also adopt a winding having the above-mentioned structure.

[0079] Please refer to Figures 22, 23A and 23B. Figures 23A and 23B respectively show the T1-T1' and T2-T2' cross-sectional views of an embodiment of the thin transformer of the present invention. As shown in the figures, the first winding set 70 and the second winding set 80 surround the hollow column 53 in the radial direction of the hollow column 13, and the first winding set 70 and the second winding set 80 are arranged concentrically on the first plate 51.

[0080] 24A and 24B respectively show a T1-T1' cross section and a T2-T2' cross section of another embodiment of the thin transformer of the present invention. In this embodiment, the thin transformer 5a includes a winding frame 50a, a pair of iron cores 60a, a first winding set 70a, and a second winding set 80a. The winding frame 50a includes a hollow column 53a. The pair of iron cores 60 are provided on both sides of the winding frame 50a. The first winding set 70a and the second winding set 80a surround the hollow column 53a concentrically in the radial direction of the hollow column 53a and are positioned between the pair of iron cores 60a. Furthermore, there is a spacing distance 90a between the second winding set 80a and the first winding set 70a.

[0081] The difference of this embodiment is that the thin transformer 1a also includes an interlayer insulating film Ia. The interlayer insulating film Ia is made of an insulating material and is disposed at a distance 90a. The thickness of the interlayer insulating film Ia is 0.2 mm or more and 13.5 mm or less. As a result, both sides of the interlayer insulating film Ia are in contact with the first winding set 70a and the second winding set 80a, respectively, and the distance 90a between the first winding set 70a and the second winding set 80a is secured, thereby increasing the leakage inductance of the thin transformer 5a.

[0082] In actual implementation, by installing the spacing distance or the interlayer insulating film, the leakage inductance can be increased by more than 15%, and the resonant inductance of the LLC circuit of the conventional transformer can be replaced, that is, the effect of the LLC circuit can be realized without the need for an external resonant inductance.

[0083] The winding with at least three insulating layers of the present invention can be applied to an isolated circuit, for example, to configure the primary winding (e.g., the first winding set 70, 70a described above), the secondary winding (e.g., the second winding 80, 80a described above) and / or the inductor winding of a transformer of the isolated circuit, so that the isolated circuit has high voltage resistance characteristics.

[0084] In one embodiment, the switching power supply may be a separated circuit. As shown in FIG. 25, the separated circuit 300 includes a power factor correction (PFC) circuit 310 and a resonant conversion circuit 320. The resonant conversion circuit 320 may be an LLC resonant circuit. The power factor correction circuit 310 includes a rectifier circuit 311 and a boost circuit 312 connected in series. The rectifier circuit 311 is electrically connected to the input terminal of the separated circuit 300, and receives an AC input voltage and converts it into a DC voltage. The boost circuit 312 is electrically connected to the rectifier circuit 311, and boosts the DC voltage.

[0085] The resonant conversion circuit 320 includes a primary circuit 321, a resonant circuit 322, and a secondary circuit 323, which are connected in series in this order. The primary circuit 321 is electrically connected to the power factor correction circuit 310. The resonant circuit 322 includes a resonant inductance Lr, a resonant capacitor Cr, and a transformer T. The transformer T includes a primary winding Np and a secondary winding Ns. The primary winding Np and the secondary winding Ns are electromagnetically coupled, and the resonant inductance Lr, the resonant capacitor Cr, and the primary winding Np are connected in series. The secondary winding Ns induces a secondary voltage based on the voltage of the primary winding Np. The secondary circuit 323 is electrically connected between the secondary winding Ns and the output end of the separated circuit 300, receives the secondary voltage generated by the secondary winding Ns, converts it into an output voltage, and outputs it from the output end of the separated circuit 300. The resonant inductance Lr may be an external physical inductance element, or may be formed by a leakage inductance formed by the gap distance between the primary winding and the secondary winding or an interlayer insulating film. When the resonant inductance Lr is an external physical inductance, the resonant inductance may comprise a winding as described above, i.e. a winding comprising a conductor (e.g. any of the conductors 11, 21, 31, 41 and A described above) and an insulating layer covering the conductor (e.g. any of the insulating structures 12, 22 and insulating layers 321, E described above).

[0086] In some embodiments of the present invention, the primary winding Np and / or the secondary winding Ns in the above-mentioned separated circuit include the above-mentioned winding, i.e., a winding having a conductor (e.g., any of the above-mentioned conductors 11, 21, 31, 41, and A) and an insulating layer covering the conductor (e.g., any of the above-mentioned insulating structures 12, 22 and insulating layers 321, E). The present invention achieves the effect of improving the withstand voltage value of the winding by covering the conductor with at least three insulating layers. For example, compared with a known three-layer insulated wire with an outer coating thickness of 0.09 mm and a withstand voltage value of about 3100 VAC, the insulating layer of the winding of the present invention has a thickness of about 0.15 mm and a withstand voltage value of about 5000 VAC. Therefore, when the separated circuit uses the winding covered with at least three insulating layers of the present invention to form an inductive component, when the input and output ends of the separated circuit are short-circuited for high voltage testing, the withstand voltage value between the primary circuit and the secondary circuit can reach about 4000 VAC to 5000 VAC.

[0087] Specifically, the rectifier circuit 311 is electrically connected to the input end of the isolated circuit 300 and has a full-bridge rectifier structure composed of four diodes d2. In another embodiment of the present invention, the rectifier circuit may be a full-bridge rectifier structure composed of four controllable switch tubes such as MOS tubes, or may be a half-bridge rectifier structure. The boost circuit 312 includes an energy storage inductor Lf, a first switch Q1, a first output capacitor Cf, and a diode d1. A first end of the energy storage inductor Lf is electrically connected to the rectifier circuit 311. A first power terminal of the first switch Q1 is electrically connected to a second end of the energy storage inductor Lf, and a second power terminal of the first switch Q1 is electrically connected to a ground terminal G. An anode end of the diode d1 is electrically connected to the first power terminal of the first switch Q1 and the second end of the energy storage inductor Lf. A first end of the first output capacitor Cf is electrically connected to the cathode end of the diode d1, and a second end of the first output capacitor Cf is electrically connected to the ground terminal G. The primary circuit 321 is an inverter circuit, and includes a second switch Q2 and a third switch Q3. The second switch Q2 and the third switch Q3 are connected in parallel between the cathode end of the diode d1 and the ground terminal G, and the resonant inductance Lr and the resonant capacitor Cr are connected in series with the primary winding Np and connected between the connection point between the second switch Q2 and the third switch Q3 and the ground terminal G. In another embodiment of the present invention, the inverter circuit may be a full-bridge inverter structure. The secondary circuit 323 includes a fourth switch Q4, a fifth switch Q5, and a second output capacitor Co. A first power terminal of the fourth switch Q4 is electrically connected to the first end of the secondary winding Ns, and a second power terminal of the fourth switch Q4 is electrically connected to the output negative terminal of the output end of the isolated circuit 300. A first power terminal of the fifth switch Q5 is electrically connected to a second end of the secondary winding Ns, and a second power terminal of the fifth switch Q5 is electrically connected to the output negative terminal of the output end of the separated circuit 300. The secondary winding Ns has a center tap terminal and is electrically connected to the output positive terminal of the output end of the separated circuit 300. A second output capacitor Co is electrically connected between the output positive terminal and the output negative terminal.

[0088] In addition, when the spacing distance between the primary winding and the secondary winding, or the leakage inductance formed by the interlayer insulating film constitutes the resonant inductance Lr, the primary winding Np and / or the secondary winding Ns in the LLC circuit can also increase the magnitude of the leakage inductance or the resonant inductance Lr if the primary winding Np and / or the secondary winding Ns in the LLC circuit is a winding having a conductor (e.g., any of the conductors 11, 21, 31, 41, and A described above) and an insulating layer covering the conductor (e.g., any of the insulating structures 12, 22 and insulating layers 321, E described above). According to JPEG0003250014000003.jpg2023 (Q is the quality factor, Lr is the resonant inductance, Cr is the resonant capacitor, and R is the load), when Lr increases, the quality factor of the circuit can be improved.

[0089] In another embodiment, as shown in FIG. 26, the isolated circuit 300a can be a flyback circuit, and includes a primary circuit 310a, a transformer T, and a secondary circuit 320a. The structure and function of the transformer T are similar to those of the transformer T shown in FIG. 25, and are denoted by the same reference numerals, and the details thereof are omitted. The primary circuit 310a includes a rectifier circuit 311a, a filter capacitor Cfa, a switch Q1a, and an RCD absorption circuit 312a composed of a resistor R, a bleed capacitor C1, and a diode d3. The rectifier circuit 311a is electrically connected to the input terminal of the isolated circuit 300a, and includes a full-bridge rectifier structure composed of four diodes d2. In another embodiment of the present invention, the rectifier circuit may be a full-bridge rectifier structure composed of four controllable switch tubes, such as MOS tubes, or may be a half-bridge rectifier structure. A first end of the filter capacitor Cfa is electrically connected to the rectifier circuit 313a and the first end of the primary winding Np, and a second end of the filter capacitor Cfa is electrically connected to the ground terminal G. The switch Q1a is connected between the second end of the primary winding Np and the ground terminal G. The resistor R and the bleed capacitor C1 are electrically connected in parallel between the first end of the filter capacitor Cfa and the cathode terminal of the diode d3. The anode terminal of the diode d3 is electrically connected between the switch Q1a and the second end of the primary winding Np.

[0090] In some embodiments, the secondary circuit 320a includes a diode d4 and an output capacitor Coa. The anode terminal of the diode d4 is electrically connected to a first end of the secondary winding Ns, and the cathode terminal of the diode d4 is connected to the output positive terminal of the output end of the isolated circuit 300a. The output capacitor Coa is connected between the output positive terminal and the output negative terminal. Also, the second end of the secondary winding Ns is electrically connected to the output negative terminal of the output end of the isolated circuit 300a.

[0091] Please refer to Figure 27. Figure 27 illustrates a voltage withstand test method applied to the isolated circuit of the present invention, which includes the following steps:

[0092] Step S100: Provide a separated circuit (for example, the separated circuit 300, 300a described above). The separated circuit includes a power factor correction circuit and a resonant conversion circuit connected in series, and the resonant conversion circuit includes a primary circuit, a resonant circuit, and a secondary circuit connected in series with each other, and the primary circuit is electrically connected to the power factor correction circuit, and the resonant circuit includes a resonant inductance, a resonant capacitor, and a transformer, and the transformer includes a primary winding and a secondary winding, and the resonant inductance, the resonant capacitor, and the primary winding are connected in series. The secondary circuit is electrically connected to the secondary winding. At least one of the primary winding, the secondary winding, and the resonant inductance has a winding including a conductor and an insulating layer / insulating structure covering the conductor, and the insulating layer / insulating structure is wound and covered along the Y-axis direction perpendicular to the X-axis direction, so that the number of insulating layers covering the conductor is at least three after one side parallel to the X-axis direction is fixed on the conductor arranged parallel to the X-axis direction. Step S200: A high voltage test is performed by shorting the input terminal and the output terminal of the separate circuit, and a withstand voltage value between the input terminal and the output terminal of the separate circuit is obtained.

[0093] As described above, by adopting a primary winding and / or secondary winding using a winding coated with at least three insulating layers according to the present invention, the withstand voltage value between the input terminal and the output terminal can be increased to 4000VAC to 5000VAC in the separated circuit.

[0094] As mentioned above, the winding of the present invention has the advantages of being easy to realize automatic processing, easy to wind smoothly, and the surface of the processed conductor is smooth and compact, which is helpful in improving the power density of the magnetic body. In addition, the material manufacturing cost is low, and at the same time, it can meet the demand for strengthened insulation. In addition, the winding manufacturing method of the present invention achieves the goal of reducing the final wire diameter of the winding under the premise of increasing the thickness of the insulation layer outside the conductor by at least three insulating layers, and not only reduces the volume of the winding set and increases the space between the winding sets, but also increases the overall height and leakage inductance of the transformer. In addition, the winding coated with at least three insulating layers manufactured by the present invention further provides advantages such as withstand voltage value and compliance with safety regulations.

[0095] It should be noted that the above-mentioned contents are preferred embodiments for explaining the present invention, and the present invention is not limited to the above-mentioned embodiments, and the scope of the present invention can be modified in various ways according to the demands of those skilled in the art without departing from the protection intended by the scope of the utility model registration claims.

Claims

1. A separate type circuit, comprising a power factor correction circuit and a resonant conversion circuit, which are connected in series in this order, the resonant conversion circuit comprising a primary circuit, a resonant circuit, and a secondary circuit, which are connected in series in this order; the primary circuit is electrically connected to the power factor correction circuit; the resonant circuit includes a resonant inductance, a resonant capacitor, and a transformer, the transformer includes a primary winding and a secondary winding, the resonant inductance, the resonant capacitor, and the primary winding are connected in series; the secondary circuit is electrically connected to the secondary winding; the primary winding and / or the secondary winding comprises a winding, the winding comprises a conductor and an insulating layer covering the conductor, the insulating layer is fixed onto the conductor with a side parallel to the X-axis direction being placed along a direction parallel to the X-axis direction, and then wrapped around the conductor along a Y-axis direction perpendicular to the X-axis direction to cover the conductor so that the number of insulating layers covering the conductor is at least three, and a withstand voltage value between an input terminal and an output terminal of the separated circuit is 4000 VAC to 5000 VAC.

2. The power factor correction circuit includes a rectifier circuit and a boost circuit connected in series in this order, the boost circuit comprises an energy storage inductor, a first switch, a diode, and a first output capacitor; a first end of the energy storage inductor electrically connected to the rectifier circuit; a first power terminal of the first switch electrically connected to a second end of the energy storage inductor and a second power terminal of the first switch electrically connected to a ground terminal; an anode end of the diode is electrically connected to the first power terminal of the first switch; 2. The isolated circuit of claim 1, wherein a first end of the first output capacitor is electrically connected to the cathode terminal of the diode, and a second end of the first output capacitor is electrically connected to the ground terminal.

3. the primary circuit includes an inverter circuit, the inverter circuit is electrically connected to the boost circuit, and the inverter circuit includes a second switch and a third switch; the third switch is connected in series with the second switch between the cathode terminal of the diode and the ground terminal; the secondary circuit includes a fourth switch, a fifth switch, and a second output capacitor; a first power terminal of the fourth switch electrically connected to a first end of the secondary winding and a second power terminal of the fourth switch electrically connected to an output negative terminal of the isolated circuit; a first power terminal of the fifth switch electrically connected to a second end of the secondary winding and a second power terminal of the fifth switch electrically connected to the output negative terminal of the isolated circuit; the second output capacitor is electrically connected between the output positive terminal and the output negative terminal of the isolated circuit; 3. The isolated circuit of claim 2, wherein the secondary winding has a center tap terminal, the center tap terminal being electrically connected to the output positive terminal of the isolated circuit.

4. 2. The isolated circuit of claim 1, wherein said winding comprises a plurality of conductors, said plurality of conductors being twisted together in a spiral having a length of up to one meter and at least 33 turns.

5. 5. The separated circuit of claim 4, wherein each of the plurality of conductors comprises a core and a coating layer, the core having a first wire diameter, the plurality of twisted conductors having a second wire diameter, and the winding having a third wire diameter, the third wire diameter being smaller than a total wire diameter of the plurality of conductors coated with at least three insulating layers, and the third wire diameter being smaller than a total wire diameter of the plurality of conductors coated with at least three insulating layers.

6. 6. The isolated circuit of claim 5, wherein the number of said plurality of conductors is 33 or more, and the second wire diameter is at least 0.55 mm.

7. 2. The isolated circuit of claim 1, wherein said insulating layer comprises insulating tape.

8. 2. The isolated circuit of claim 1, further comprising a spacing distance between said primary winding and said secondary winding.

9. 9. The isolated circuit of claim 8, further comprising an interlayer insulating film disposed between said gaps.

10. 10. The isolated circuit of claim 9, wherein the resonant inductance is a leakage inductance formed by the spacing distance or an interlayer insulating film.

11. 2. The isolated circuit of claim 1, wherein when the resonant inductance is an external inductance, the resonant inductance comprises the winding.

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