transformer

Abstract

To provide a transformer simple in manufacturing process, capable of easily achieving automation, stable in product quality and size, high in product commonality and small in volume.SOLUTION: A transformer includes a core 2, a bobbin 3, two first coils 41, a second coil, a first circuit board 5 and a second circuit board 6. The core includes a first magnetic body 21 and a second magnetic body 22. The bobbin includes a bobbin main body 31, a bobbin channel 32 and a winding space part 33. The bobbin channel penetrates both opposite surfaces of the bobbin main body. The winding space part is formed on an outer periphery surface of the bobbin main body. The two first coils are wound around the winding space part. The second coil is wound around the winding space part, and is positioned between the two first coils. The circuit board has circuit board channels 52 and 62 connected to the bobbin channel. A first intermediate column 214 and a second intermediate column 224 of the core penetrate the circuit board channel and the bobbin channel.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a transformer, and more particularly to a transformer in which a coil is formed using a circuit board. [Background technology]

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

[0003] Transformers in frequency converters usually adopt a multi-coil design for different functions. In conventional multi-coil transformers, each coil is wound around the core in an irregular arrangement, which makes the actual working voltage of the transformer prone to drift. The manufacturing process is complicated and cannot be automated. Therefore, conventional transformers have disadvantages such as increased installation costs, reduced efficiency in industrial automation, and unstable product characteristics and dimensions.

[0004] Therefore, there is currently an urgent need to develop a transformer that overcomes the above drawbacks. Summary of the Invention [Problem to be solved by the invention]

[0005] An object of the present invention is to provide a transformer in which the inner first coil 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, i.e., the outer first coil, second coil, and inner first coil are arranged sequentially in the stacking direction. By arranging the inner first coil, outer first coil, and second coil of the transformer of the present invention as described above, the leakage inductance of the transformer can be significantly reduced, and because the inner first coil, outer first coil, and second coil of the transformer are arranged in an orderly manner and are not easily wound alternately, the transformer of the present invention has the advantages of a simple manufacturing process, ease of automation, stable product quality and dimensions, high product commonality, and small volume. [Means for solving the problem]

[0006] To achieve the above object, one embodiment of the present invention is a transformer comprising a core, a bobbin, a first inner coil, a first outer 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 penetrating opposing faces of the bobbin body, and the winding space portion is formed on the outer peripheral surface of the bobbin body. The first inner coil and the first outer coil are wound in the winding space portion, and the first inner coil is located between the outer peripheral surface of the bobbin body. The second coil is wound in the winding space portion and located between the first inner coil and the outer peripheral surface of the bobbin body. The at least one circuit board has a circuit board through-hole connected to the bobbin through-hole, and a portion of the core passes through the circuit board through-hole and the bobbin through-hole. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a schematic diagram illustrating an assembled structure of a transformer according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a schematic exploded view of the transformer shown in FIG. [Figure 3] 2 is a schematic cross-sectional view of the transformer shown in FIG. 1 taken along the line AA'. DETAILED DESCRIPTION OF THE INVENTION

[0008] Some exemplary embodiments illustrating 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 in different aspects, all without departing from the scope of the present invention, and that the description and drawings are illustrative in nature and are not intended to limit the present invention.

[0009] 1, 2, and 3, Fig. 1 is a schematic diagram of an assembled structure of a transformer according to a first embodiment of the present invention, Fig. 2 is a schematic diagram of an exploded structure of the transformer shown in Fig. 1, and Fig. 3 is a schematic diagram of a partial cross-sectional structure along the A-A' direction of the transformer shown in Fig. 1. 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 this 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 connected to opposite ends of the first main surface 211, respectively, 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 located on opposite sides of the transformer 1, respectively. The third side surface 222 and the fourth side surface 223 are respectively connected to opposite ends of the second main surface 221 and located on opposite sides of the transformer 1, the third side surface 222 being disposed in spatial correspondence with the first side surface 212 and being located between the second main surface 221 and the first main surface 211, and the fourth side surface 223 being disposed in spatial correspondence with the second side surface 213 and being 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 being located between the third side surface 222 and the fourth side surface 223, the second intermediate column 224 being disposed in spatial correspondence with the first intermediate column 214 and being located between the second main surface 221 and the first main surface 211.

[0011] The reel 3 includes a reel body 31, a reel through-hole 32, and at least one winding space 33. To simplify the drawing, structural features of the core 2 are not shown in FIG. 3. As shown in FIGS. 2 and 3, the reel body 31 has a first wall 311, a second wall 312, and an outer circumferential surface 313. The first wall 311 and the second wall 312 of the reel body 31 are located at opposite ends of the reel body. The first wall 311 is located between the first main surface 211 and the second wall 312 of the first magnetic body 21. The second wall 312 is located between the second main surface 221 of the second magnetic body 22 and the first wall 311. The outer circumferential surface 313 of the reel body 31 is located between the first wall 311 and the second wall 312. 2 and 3 , a first wall surface 311 of the reel body 31 protrudes from the corresponding outer peripheral surface 313, and a second wall surface 312 of the reel body 31 protrudes from the corresponding outer peripheral surface 313. In this embodiment, the reel 3 has only one winding space 33, which 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. Thus, the winding space 33 is formed on the outer peripheral surface 313 of the reel body 31. The reel body 31 has a hollow structure, and the hollow structure defines a reel through hole 32 that penetrates the first wall surface 311 and the second wall surface 312 of the reel body 31.

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

[0013] The wiring within the first circuit board 5 constitutes another portion of the primary coil of the transformer 1. As shown in FIG. 1 , the first circuit board 5 is located between the first main surface 211 of the first magnetic body 21 and the first wall surface 311 of the bobbin body 31, and is also located 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 body 51 and a first circuit board through hole 52. The first circuit board through hole 52 penetrates the first circuit board body 51 and spatially corresponds to the bobbin through hole 32. The wiring within the second circuit board 6 constitutes another portion of the secondary coil of the transformer 1. As shown in FIGS. 1 and 2 , the second circuit board 6 is located between the second main surface 221 of the second magnetic body 22 and the second wall surface 312 of the bobbin body 31, and is also located 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, and the second circuit board through hole 62 penetrates the second circuit board main body 61 and spatially corresponds to the reel through hole 32. The first circuit board through hole 52, the second circuit board through hole 62, and the reel through hole 32 are in communication with each other, 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 reel through hole 32, 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 reel 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 reel through hole 32. As a result, the first inner coil 41, the first outer 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 and the third side surface 222 of the second magnetic body 22 are connected to each other, and the second side surface 213 of the first magnetic body 21 and the fourth side surface 223 of the second magnetic body 22 are connected to each other, thereby assembling the transformer 1 (as shown in FIG. 1).

[0014] As can be seen from the above, in the transformer 1 of the present invention, the inner first coil 41 is located between the outer first coil 41 and the outer peripheral surface 313 of the bobbin body 31, and the second coil 42 is located between the inner first coil and the outer first coil. In other words, the outer first coil 41, the second coil 42, and the inner first coil 41 are arranged sequentially in the stacking direction. Therefore, while the coils of conventional transformers are wound irregularly 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. This allows the leakage inductance of the transformer 1 to be significantly reduced. Furthermore, the inner first coil 41, the outer first coil 41, and the second coil 42 of the transformer 1 are arranged in an orderly manner and are not wound alternately. Therefore, the transformer 1 of the present invention has the advantages of a simple manufacturing process, ease of automation, stable product quality and dimensions, high product commonality, and small volume.

[0015] 1 and 2, the reel body 31 further has a first inserted portion 314 and a second inserted portion 315. The first inserted portion 314 and the second inserted portion 315 are respectively installed on opposite sides of the reel body 31, and the first inserted portion 314 is connected to one end of the first wall surface 311 of the reel body 31 and is installed offset from the reel through-hole 32 without covering it. When the transformer 1 is assembled, that is, when the first intermediate column 214 of the first magnetic body 21 of the core 2 passes through the first circuit board through-hole 52 and the bobbin through-hole 32, the second intermediate column 224 of the second magnetic body 22 of the core 2 passes through the second circuit board through-hole 62 and the bobbin 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 bobbin through-hole 32, as shown in Fig. 1 , the first inserted portion 314 is adjacent to the first main surface 211 of the first magnetic body 21, and an edge of the first inserted portion 314 is located on the same plane as the first main surface 211, which plane is parallel to the first wall surface 311 of the bobbin body 31. In this embodiment, the first inserted portion 314 further has a first inner recess 316 formed by recessing the top surface of the first inserted portion 314 and in which a first insertion hole 317 is provided. The second inserted portion 315 is connected to one end of the second wall surface 312 of the reel body 31 and is installed offset from the reel through hole 32 without covering the reel 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 passes through the first circuit board through hole 52 and the reel through hole 32, and the second intermediate column 224 of the second magnetic body 22 of the core 2 passes through the second circuit board through hole 62 and the reel 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 reel through hole 32, the second inserted portion 315 is adjacent to the second main surface 221 of the second magnetic body 22, and an edge of the second inserted portion 315 is located on the same plane as the second main surface 221, and this plane is parallel to the second wall surface 312 of the reel body 31, as shown in FIG. In this embodiment, the second insertion portion 315 further has a second internal recess 318 formed by recessing the top surface of the second insertion portion 315 and having a second insertion hole. Although the position of the second insertion hole is not shown in Figure 2, it is clear that the installation position of the second insertion hole corresponds to the installation position of the first insertion hole 317.

[0016] 2 , 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. The first circuit board body 51 is inserted into the first insertion hole 317 through the bottom surface of the first insertion portion 314, so that at least a portion of the first sub-body 511 is located in the first internal recess 316, and at least a portion 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 reel body 31 and the first main surface 211 of the first magnetic body 21. The first circuit board through-hole 52 communicates with the reel 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 reel through-hole 32. The second circuit board body 61 includes a third sub-body 611 and a fourth sub-body 612 integrally formed with each other. 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. The second circuit board body 61 is inserted into the second insertion hole through the bottom surface of the second insertion portion 315, so that at least a portion of the third sub-body 611 is located in the second internal recess, and at least a portion 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 reel body 31 and the second main surface 221 of the second magnetic body 22. The second circuit board through-hole 62 communicates with the reel 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 reel through-hole 32. In some embodiments, the width W2 of the second sub-body 512 is equal to or less than the width W1 of the first sub-body 511, so that 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 equal to or less than the width W3 of the third sub-body 611, so that the second circuit board body 61 can be inserted into the second insertion hole 317 through the top surface of the second insertion portion 315.

[0017] Of course, in some embodiments, the transformer may not include the first inserted portion 314 and the second inserted portion 315, and the first circuit board 5 may be disposed between the first main surface 211 of the first magnetic body 21 and the reel body 31 simply by having the first intermediate column 214 of the first magnetic body 21 sequentially pass through the first circuit board through-hole 52 and the reel body through-hole 32. Similarly, the second circuit board 6 may be disposed between the second main surface 221 of the second magnetic body 22 and the reel body 31 simply by having the second intermediate column 224 of the second magnetic body 22 sequentially pass through the second circuit board through-hole 62 and the reel body through-hole 32.

[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. In other words, the outer first coil, second coil, and inner first coil are arranged sequentially in the stacking direction. Therefore, while the coils of conventional transformers are wound irregularly around the core, the inner first coil, outer first coil, and second coil of the transformer of the present invention are arranged as described above, which makes it possible to significantly reduce the leakage inductance of the transformer. In addition, the inner first coil, outer first coil, and second coil of the transformer are arranged in an orderly manner and are not wound alternately. Therefore, the transformer of the present invention has the advantages of a simple manufacturing process, ease of automation, stable product quality and dimensions, high product commonality, and small volume. [Explanation of symbols]

[0019] 1: Transformer 2: Core 21: First magnetic body 211: First main surface 212:1st side 213:Second side 214: First intermediate column 22:Second magnetic material 221: Second main surface 222:Third side 223:Fourth side 224: Second intermediate column 3: Reel frame 31: Reel body 311: First wall 312: Second wall 313: Outer surface 314: First insertion part 315: Second insertion part 316: 1st inner recess 317: First insertion hole 318:Second inner recess 32: Reel frame through hole 33: Winding space 41: First coil 42: Second coil 5: 1st 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: 4th 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 passing through opposing surfaces 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 portion; an inner first coil located between the outer first coil and the outer peripheral 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 the second coil and the first circuit board is equal to a shortest distance between the second coil and the second circuit board; the second circuit board has a second circuit board through-hole and is located between the second magnetic body and the bobbin body; the first circuit board is located between the first magnetic body and the spool body, and has a first circuit board through hole; the first circuit board through hole, the second circuit board through hole, and the spool 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 spool through hole, 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 being disposed at opposite ends of the reel body, the outer circumferential surface of the reel body being located between the first wall surface and the second wall surface, the reel through hole penetrating the first wall surface and the second wall surface of the reel body, the first insertion portion being connected to one end of the first wall surface of the reel body, the first insertion portion being positioned offset from the reel through hole without covering it, the first insertion portion having a first internal recessed portion provided with a first insertion hole, the second insertion portion being connected to one end of the second wall surface of the reel body, the second insertion portion being positioned offset from the reel through hole without covering it, and the second insertion portion having a second internal recessed portion provided with a second insertion hole.

2. 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; 2. The transformer of claim 1, 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 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 bobbin through hole.

3. 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, 2. The transformer according to claim 1, 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.

4. 2. The transformer according to 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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