Transformer and shielding structure

Abstract

A transformer and a shielding structure are provided. The transformer comprises a primary conductive unit, a secondary conductive unit, a core set, and a shielding structure, wherein the secondary conductive unit is electromagnetically coupled to the primary conductive unit. At least one shielding portion of the shielding structure is disposed between at least one main winding of the primary conductive unit and the secondary conductive unit. Arranging the bent shielding structure between the primary conductive unit and the secondary conductive unit forms a shield and reduce electromagnetic interference.

Description

Technical Field

[0001] This invention relates to a transformer and its shielding structure, and more particularly to a transformer and its shielding structure of the interleaved type without winding frame. Prior Technology

[0002] When a power supply is operating, the high-frequency switching of the transformer generates noise at multiple frequencies, resulting in electromagnetic interference (EMI). To eliminate conducted or radiated EMI noise generated by the transformer, a shielding copper foil is typically added between the primary and secondary sides of the transformer and grounded.

[0003] However, for bobbin-less interleaved transformers, copper sheets are usually used on the secondary side to improve efficiency due to high current output. However, the tape wrapped around the copper sheets is insufficient to meet the safety specifications for reinforcing insulation distance, making it difficult to connect the shielding copper foil in parallel to the primary side grounding terminal. As a result, the shielding copper foil connected to the secondary side grounding terminal cannot produce a good shielding effect.

[0004] Therefore, in order to overcome the shortcomings and deficiencies of the existing technology, it is necessary to provide an improved transformer and shielding structure to solve the problems existing in the above-mentioned conventional technology. Summary of the Invention

[0005] The main objective of this invention is to provide a transformer and a shielding structure, which utilizes a bent shielding structure placed between the primary conductive unit and the secondary conductive unit to form a shield and reduce electromagnetic interference.

[0006] To achieve the above objectives, the present invention provides a transformer, which includes a primary conductive unit, a secondary conductive unit, a core assembly, and a shielding structure; the primary conductive unit includes at least one main winding; the secondary conductive unit is alternately arranged with the primary conductive unit; the core assembly has a protrusion and an accommodating space, the main winding and the secondary conductive unit are disposed in the accommodating space and wound around the protrusion; the shielding structure includes at least one bent portion and two shielding portions, the two shielding portions extending from both ends of the bent portion respectively, wherein at least one shielding portion of the shielding structure is disposed between at least one main winding of the primary conductive unit and the secondary conductive unit.

[0007] In one embodiment of the present invention, the secondary conductive unit includes two metal sheets, at least one main winding of the primary conductive unit is disposed between the two metal sheets, and at least one shielding part of the shielding structure is disposed between the corresponding main winding and the corresponding metal sheet.

[0008] In one embodiment of the present invention, the secondary conductive unit includes a plurality of metal sheets, a plurality of main windings of the primary conductive unit are disposed between the plurality of metal sheets, and a plurality of shielding parts of the shielding structure are respectively disposed between the corresponding main windings and the corresponding metal sheets.

[0009] In one embodiment of the present invention, each metal sheet has a shoulder, two extensions and an opening, the two extensions are respectively connected to the two sides of the shoulder, the opening is formed between the two extensions, and the two shielding parts are respectively located on the two sides of the opening.

[0010] In one embodiment of the present invention, the plurality of metal sheets are arranged in an alternating manner such that the openings of two adjacent metal sheets face opposite directions, wherein the plurality of metal sheets with openings facing a first direction are connected in parallel, and the plurality of metal sheets with openings facing a second direction are connected in parallel, wherein the first direction and the second direction are opposite.

[0011] In one embodiment of the present invention, at least one bent portion of the shielding structure spans the shoulder of the corresponding metal sheet.

[0012] In one embodiment of the present invention, at least one bent portion of the shielding structure is disposed across the corresponding main winding.

[0013] In one embodiment of the present invention, the shielding portion of the shielding structure covers at least the shoulder and two extensions of the metal sheet in a projected area of ​​the corresponding metal sheet.

[0014] In one embodiment of the present invention, the plurality of bent portions of the shielding structure are respectively located on a first side and a second side of the opening of the plurality of metal sheets, and the plurality of bent portions located on the first side correspond to the plurality of bent portions located on the second side.

[0015] In one embodiment of the present invention, the plurality of shielding portions located on the first side correspond to the plurality of shielding portions located on the second side.

[0016] To achieve the above objectives, the present invention provides a shielding structure disposed in a transformer. The transformer includes a primary conductive unit and a secondary conductive unit, with the secondary conductive unit and the primary conductive unit being arranged alternately. The shielding structure includes at least one bent portion and two shielding portions. The two shielding portions extend from both ends of the bent portion, respectively. The at least one shielding portion of the shielding structure is disposed between at least one main winding of the primary conductive unit and the secondary conductive unit.

[0017] In one embodiment of the present invention, the shielding structure includes a starting end and a ending end, the starting end and the ending end being electrically connected to an external component respectively.

[0018] In one embodiment of the present invention, the shielding structure is a long strip structure formed by covering a conductive sheet with an insulating layer.

[0019] In one embodiment of the present invention, the shielding structure is a long strip structure formed by connecting multiple conductive wires side by side.

[0020] In one embodiment of the present invention, the secondary conductive unit includes at least one metal sheet, the metal sheet having a shoulder, two extensions and an opening, the two extensions being connected to both sides of the shoulder respectively, the opening being formed between the two extensions, and a width of the shielding structure being greater than or equal to a width of the corresponding extension.

[0021] As described above, this invention, by placing a bent shielding structure between the primary and secondary conductive units, forms a shield between them, reducing electromagnetic interference and preventing excessively high induced voltages, thereby improving the stability and safety of the power supply system. Furthermore, by pre-processing and connecting the shielding structure with the metal sheet, the manufacturing process is shortened. Simple Explanation of the Diagram

[0022] Figure 1 is a schematic diagram of an embodiment of the transformer according to the present invention.

[0023] Figure 2 is a schematic diagram of the decomposition of Figure 1.

[0024] Figure 3 is a partial schematic diagram of the transformer in Figure 1.

[0025] Figure 4 is a cross-sectional view of Figure 1.

[0026] Figure 5 is a partial schematic diagram of the shielding structure of the transformer in Figure 1.

[0027] Figure 6 is a schematic diagram of another form of the shielding structure of an embodiment of the transformer according to the present invention.

[0028] Figure 7 is a schematic diagram of an embodiment of the transformer according to the present invention.

[0029] Figure 8 is an exploded view of Figure 7.

[0030] Figure 9 is a partial schematic diagram of the transformer in Figure 7.

[0031] Figure 10 is a cross-sectional view of Figure 7. Implementation

[0032] To make the above and other objects, features, and advantages of the present invention more apparent and understandable, embodiments of the present invention will be specifically described below in conjunction with the accompanying drawings. Furthermore, the directional terms used in this invention, such as up, down, top, bottom, front, back, left, right, inside, outside, side, surrounding, center, horizontal, transverse, vertical, longitudinal, axial, radial, uppermost, or lowermost, are merely for reference to the directions in the accompanying drawings. Therefore, the directional terms used are for illustrating and understanding the present invention, and not for limiting the present invention. It should be noted that the drawings are simplified schematic diagrams; therefore, only elements and combinations related to the present invention are shown to provide a clearer description of the basic structure or implementation method of the present invention, while the actual elements and layout may be more complex. In addition, for ease of explanation, the elements shown in the various drawings of the present invention are not drawn to scale according to the actual number, shape, and size; the detailed scale can be adjusted according to design requirements.

[0033] Referring to Figure 1, which is a schematic diagram of an embodiment of the transformer of the present invention, the transformer includes a primary conductive unit 2, a secondary conductive unit 3, an iron core assembly 4, and a shielding structure 5. The detailed structure, assembly relationship, and operating principle of each component will be described in detail below.

[0034] As shown in Figures 1, 2, and 3, Figure 2 is an exploded view of Figure 1, and Figure 3 is a partial schematic diagram of the transformer in Figure 1. The secondary conductive unit 3 and the primary conductive unit 2 are arranged alternately. Specifically, the primary conductive unit 2 includes a main winding 21, and the secondary conductive unit 3 includes two metal sheets 31 and 32. The main winding 21 of the primary conductive unit 2 is disposed between the two metal sheets 31 and 32 (i.e., the secondary conductive unit 3 and the primary conductive unit 2 are arranged alternately). The core assembly 4 has a accommodating space 42 with a protrusion 41 and corresponding shapes of the main winding 21 and the two metal sheets 31 and 32 to accommodate the main winding 21 and the two metal sheets 31 and 32 (i.e., the main winding 21 and the secondary conductive unit 3 are disposed in the accommodating space 42). Moreover, the main winding 21 and the secondary conductive unit 3 are wound around the protrusion 41 of the core assembly 4 (i.e., the protrusion 41 of the core assembly 4 passes through the main winding 21 and the two metal sheets 31 and 32).

[0035] In this embodiment, the main winding 21 is made of conductive material. According to actual needs, the conductive wire is spirally wound with a specific number of turns, and a through hole is formed in the center of the main winding 21. The two ends of the conductive wire extend outward from the periphery of the main winding 21, and the starting and ending ends of the conductive wire winding serve as terminals (not shown). In addition, the core assembly 4 is made of magnetic material, and the core assembly 4 includes a first core 43 and a second core 44. The first core 43 and the second core 44 are provided with protrusions 41, which are configured to pass through the main winding 21 and the metal sheets 31 and 32 respectively. Moreover, the first core 43 and the second core 44 cover at least a portion of the primary conductive unit 2 and the secondary conductive unit 3 to form an electromagnetic circuit, so that the primary conductive unit 2 and the secondary conductive unit 3 are electromagnetically coupled.

[0036] As shown in Figures 3 and 4, Figure 4 is a cross-sectional view of Figure 1. The shielding structure 5 includes multiple bends 51 and multiple shielding portions 52. Adjacent shielding portions 52 extend in the same direction from both ends of the corresponding bends 51. The shielding portions 52 of the shielding structure 5 are disposed between the main winding 21 of the primary conductive unit 2 and the secondary conductive unit 3. Specifically, adjacent shielding portions 52 of the shielding structure 5 are attached to both sides of the main winding 21, such that adjacent shielding portions 52 are located between the main winding 21 and the corresponding metal sheets 31 and 32. In addition, the shielding structure 5 also includes a starting end 54 and an ending end 55, which are respectively connected to two pins for electrical connection with an external component, such as a circuit board (not shown).

[0037] In this embodiment, as shown in Figure 2, the starting end 54 and the ending end 55 of the shielding structure 5 correspond to the first segment D1 and the second segment D2 of the U-shaped metal sheet 31, respectively. Both the first segment D1 and the second segment D2 of the U-shaped metal sheet 31 are shielding parts 52. The shielding structure 5 extends from the starting end 54 in a first direction (upwards) through the gap between the first segment D1 of the metal sheet 31 and the main winding 21, bends at one end of the main winding 21, and then extends in a second direction (downwards) through the gap between the main winding 21 and the first segment D1 of the metal sheet 32. The gap is such that at one end of the first segment D1 of the metal sheet 32, it bends and extends in the first direction; then, the shielding structure 5 winds around the second segment D2 of the metal sheet 32 ​​via the U-shaped shielding part 53 and extends in the second direction. At one end of the second segment D2 of the metal sheet 32, it bends and extends in the first direction, passing through the gap between the second segment D2 of the metal sheet 32 ​​and the main winding 21. At one end of the main winding 21, it bends and extends in the second direction, passing through the gap between the main winding 21 and the second segment D2 of the metal sheet 31. Finally, the shielding structure 5 extends to the end 55.

[0038] Figure 5 shows a partial schematic diagram of the shielding structure of the transformer in Figure 1. In this embodiment, the shielding structure 5 is a long strip structure formed by connecting multiple conductive wires side by side, and then forming a bent part 51 and a shielding part 52 through bending. However, other embodiments are also possible. For example, the shielding structure 5 can be a long strip structure formed by covering a conductive sheet with an insulating layer. It should be noted that the shielding structure 5 of the present invention can be pre-processed and connected with the long strip structure and the metal sheets 31 and 32 together before being fitted into the iron core assembly 4, which can effectively shorten the manufacturing process.

[0039] As shown in Figure 2, in this embodiment, the two metal plates 31 and 32 are, for example, U-shaped. When the first iron core 43 and the second iron core 44 are assembled, the two ends of the metal plates 31 and 32 are exposed outside the iron core assembly 4, and the two ends of the two metal plates 31 and 32 are used for electrical connection with a circuit board or an external component (not shown). Specifically, each metal plate 31 and 32 has a shoulder A, two extensions B, and an opening C. The two extensions B are respectively connected to the two sides of the shoulder A, and the opening C is formed between the two extensions B, wherein two shielding parts 52 are respectively located on the two sides of the opening C.

[0040] Figure 6 shows a schematic diagram of another form of the shielding structure of an embodiment of the transformer of the present invention. The shielding structure 5 of the present invention further includes a U-shaped shielding portion 53 connected between the two shielding portions 52, and the U-shaped shielding portion 53 is away from the bending portion 51. The U-shaped shielding portion 53 can cover the shoulder A of the metal sheet 32, and the width of the U-shaped shielding portion 53 is more than half the width of the shoulder A of the metal sheet 32. The two shielding portions 52 can cover the two extensions B of the metal sheet 32, and the width of the shielding portion 52 is more than half the width of the extensions B of the metal sheet 32. This ensures that the shielding portions 52 and the U-shaped shielding portion 53 of the shielding structure 5 cover at least the two extensions B and the shoulder A of the metal sheet 32 ​​in a projected area. Preferably, the width of the shielding portions 52 and the U-shaped shielding portion 53 of the shielding structure 5 is greater than or equal to the width of the extensions B and the shoulder A of the metal sheet 32, thereby increasing the area of ​​the metal sheet 32 ​​that is shielded and improving the shielding effect of the shielding structure 5.

[0041] In addition, the two bends 51 of the shielding structure are located on a first side and a second side of the opening C of the corresponding metal sheet 32, respectively, and the bend 51 on the first side corresponds to the bend 51 on the second side.

[0042] Referring to Figures 7 and 8, Figure 7 is a schematic diagram of another embodiment of the transformer of the present invention, and Figure 8 is an exploded schematic diagram of Figure 7. The secondary conductive unit 3 of the present invention includes a plurality of metal sheets 31, 32, 33, and 34, and the plurality of main windings 21, 22, and 23 of the primary conductive unit 2 of the present invention are disposed between the plurality of metal sheets 31, 32, 33, and 34.

[0043] As shown in Figures 8, 9, and 10, Figure 9 is a partial schematic diagram of the transformer in Figure 7, and Figure 10 is a cross-sectional view of Figure 7. The shielding structure 5 of the present invention has multiple shielding portions 52 respectively disposed between the corresponding main windings 21, 22, 23 and the corresponding metal sheets 31, 32, 33, 34. The shielding structure 5 has multiple bent portions 51 spanning the corresponding main windings 21, 22, 23 and the shoulders A of the corresponding metal sheets 32, 34. The multiple metal sheets 31, 32, 33, 34 are arranged alternately, such that the openings C of adjacent metal sheets 31, 32, 33, 34 face opposite directions. The metal sheets 32, 34 with openings C facing upwards are connected in parallel, and the metal sheets 31, 33 with openings C facing downwards are connected in parallel.

[0044] In this embodiment, as shown in Figure 8, the starting end 54 and the ending end 55 of the shielding structure 5 correspond to the first segment D1 and the second segment D2 of the U-shaped metal sheet 31, respectively. Both the first segment D1 and the second segment D2 of the U-shaped metal sheet 31 are shielding parts 52. The shielding structure 5 extends from the starting end 54 in a first direction (upward) through the gap between the first segment D1 of the metal sheet 31 and the main winding 21, bends at one end of the main winding 21, and then extends in a second direction (downward) through the gap between the main winding 21 and the first segment D1 of the metal sheet 32. It then bends at one end of the first segment D1 of the metal sheet 32 ​​towards the second direction (downward). Extending in one direction, the shielding structure 5 is wound in the same way as the main winding 21 in the main windings 22 and 23, which will not be described again here; then, the shielding structure 5 is wound through the U-shaped shielding part 53 to the second segment D2 of the metal sheet 34 and extends in the second direction. At one end of the second segment D2 of the metal sheet 34, it is bent and extends in the first direction, passing through the gap between the second segment D2 of the metal sheet 34 and the main winding 23. At one end of the main winding 23, it is bent and extends in the second direction again, passing through the gap between the main winding 23 and the second segment D2 of the metal sheet 33. The subsequent winding method is the same. Finally, the shielding structure 5 extends to the end 55.

[0045] Based on the above structure, the shielding structure 5 located between the primary conductive unit 2 and the secondary conductive unit 3 can form a shield between the main windings 21, 22, 23 and the metal sheets 31, 32, 33, 34 in the transformer, thereby reducing electromagnetic interference. For example, in a transformer without the shielding structure 5, its EMI is only -0.46dB, while in a transformer with the shielding structure 5, its EMI drops to -3.18dB. Therefore, the shielding structure 5 of the present invention can effectively reduce the impact of EMI.

[0046] As described above, by bending the shielding structure 5 between the primary conductive unit 2 and the secondary conductive unit 3, the present invention can form a shield between the primary conductive unit 2 and the secondary conductive unit 3, thereby reducing electromagnetic interference and avoiding the generation of excessively high induced voltage, thus improving the stability and safety of the power supply system. Furthermore, by pre-processing and connecting the shielding structure 5 with the metal sheets 31 and 32, the manufacturing process can be shortened.

[0047] Although the present invention has been disclosed by way of embodiments, it is not intended to limit the present invention. Any person skilled in the art may make various modifications and alterations without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

[0048] 2: Primary conductive unit 21, 22, 23: Main winding 3: Secondary conductive unit 31, 32, 33, 34: Metal sheets D1: First paragraph D2: Second paragraph 4: Core Assembly 41:convex part 42: Storage space 43: First Iron Core 44: Second iron core 5: Shielding structure 51: Bending section 52: Shielding section 53: U-shaped shielding part 54: Starting end 55: Ending A: Shoulder B: Extension Section C: Opening

Claims

1. A transformer, comprising: a primary conducting unit including at least one main winding; a secondary conducting unit alternately disposed with the primary conducting unit; a core assembly having a protrusion and a receiving space, wherein the main winding and the secondary conducting unit are disposed in the receiving space and wound around the protrusion; and a shielding structure including a plurality of bends and a plurality of shields, wherein two adjacent shields extend from the two ends of corresponding bends, wherein at least one shield of the shielding structure is disposed between at least one main winding of the primary conducting unit and the secondary conducting unit.

2. The transformer as claimed in claim 1, wherein the secondary conductive unit comprises two metal sheets, at least one main winding of the primary conductive unit is disposed between the two metal sheets, and at least one shielding part of the shielding structure is disposed between the corresponding main winding and the corresponding metal sheet.

3. The transformer as claimed in claim 1, wherein the secondary conductive unit comprises a plurality of metal sheets, a plurality of main windings of the primary conductive unit are disposed between the metal sheets, and a plurality of shielding portions of the shielding structure are respectively disposed between the corresponding main windings and the corresponding metal sheets.

4. The transformer as claimed in claim 3, wherein each metal sheet has a shoulder, two extensions and an opening, the two extensions being connected to both sides of the shoulder, the opening being formed between the two extensions, and the two shields being located on both sides of the opening.

5. The transformer as claimed in claim 4, wherein the metal strips are arranged in an alternating manner such that the openings of adjacent metal strips are in opposite directions, wherein the metal strips with openings in a first direction are connected in parallel, and the metal strips with openings in a second direction are connected in parallel, wherein the first direction and the second direction are in opposite directions.

6. The transformer as claimed in claim 4, wherein at least one bend of the shielding structure spans the shoulder of the corresponding metal sheet.

7. The transformer as claimed in claim 4, wherein at least one bend of the shielding structure spans across the corresponding main winding.

8. The transformer as claimed in claim 4, wherein the shielding portion of the shielding structure covers at least two extensions of the corresponding metal sheet in a projected area.

9. The transformer as claimed in claim 4, wherein the plurality of bent portions of the shielding structure are respectively located on a first side and a second side of the opening of the metal sheets, and the bent portions located on the first side correspond to the bent portions located on the second side.

10. The transformer as claimed in claim 9, wherein the plurality of shielding portions located on the first side correspond to the plurality of shielding portions located on the second side.

11. A shielding structure disposed in a transformer, the transformer including a primary conductive unit and a secondary conductive unit, the secondary conductive unit being alternately disposed with respect to the primary conductive unit, the shielding structure including: a plurality of bends; and a plurality of shielding portions, two adjacent shielding portions extending from the two ends of corresponding bends; wherein at least one shielding portion of the shielding structure is disposed between at least one main winding of the primary conductive unit and the secondary conductive unit.

12. The shielding structure as claimed in claim 11, wherein the shielding structure includes a starting end and a ending end, the starting end and the ending end being electrically connected to an external component, respectively.

13. The shielding structure as described in claim 11, wherein the shielding structure is an elongated structure formed by covering a conductive sheet with an insulating layer.

14. The shielding structure as described in claim 11, wherein the shielding structure is a long strip structure formed by connecting multiple conductive wires side by side.

15. The shielding structure as claimed in claim 11, wherein the secondary conductive unit comprises at least one metal sheet having a shoulder, two extensions and an opening, the two extensions being respectively connected to both sides of the shoulder, the opening being formed between the two extensions, and a width of the shielding structure being greater than or equal to a width of the corresponding extension.

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