Bobbin and magnetic component

Abstract

This invention relates to a bobbin for supporting an insulated winding, comprising a base having an outer surface, around which the winding is wound to define a winding axis; wherein the outer surface includes at least one threaded portion helically arranged along the longitudinal axis of the base, the threaded portion defining a threaded protrusion and a threaded base; the winding includes a plurality of radial winding layers stacked in a radial direction perpendicular to the winding axis, and at least one radial winding layer is inserted into at least one threaded portion. The invention also relates to a magnetic component including a bobbin. The bobbin provided by this invention has a compact size, can be efficiently cooled, and allows for simple and efficient manufacturing.

Description

Technical Field

[0001] This invention relates to a bobbin for supporting insulated windings. Furthermore, the invention also relates to a magnetic component comprising at least one such bobbin. Prior Technology

[0002] Typically, for example in a transformer, the bobbin used to support the electrical windings is known.

[0003] For example, a bobbin structure for a flyback transformer is known from Japanese Patent JP H07-130562 A. In this structure, the low-voltage bobbin includes helical slots for providing windings therein. The windings themselves are litz wire and are uninsulated. Therefore, the helical slots provide insulation between adjacent winding layers along the winding axis. Furthermore, this known flyback transformer includes a low-voltage bobbin and a high-voltage bobbin. The input primary winding is wound on the low-voltage bobbin, and the high-voltage secondary output winding is wound on the high-voltage bobbin outside the low-voltage bobbin. In other words, this flyback transformer includes a low-voltage bobbin for the primary winding and a high-voltage bobbin for the secondary winding. These bobbins are separated and insulated from each other by epoxy resin.

[0004] The flyback transformer in Japanese Patent JP H07-130562 A has several drawbacks. One is that the bobbin configuration requires multiple bobbins to form the primary and secondary windings. Furthermore, due to the lack of conductor insulation and the helical slot configuration, the stranded wires cannot be stacked radially. In particular, no part of the winding can come into contact with other parts of the same winding without affecting the number of turns and electrical diameter due to short circuits. Therefore, it is impossible to radially stack different winding sections, such as the primary and secondary windings. Moreover, especially because multiple bobbins are required to provide the primary and secondary windings, the flyback transformer in Japanese Patent JP H07-130562 A is very space-consuming, and its cooling performance is inefficient.

[0005] Japanese Patent JP 7168902 B2 discloses a bobbin and coil assembly. The bobbin includes multiple winding separator flanges that separate adjacent winding portions along the winding axis of each winding section. The winding separator flanges form on the outer periphery of the bobbin. Adjacent winding portions formed in each winding separator flange are connected by a connecting slot. The resulting bobbin and coil assembly suffers from drawbacks in terms of ease of manufacture and efficiency, particularly when considering automated winding processes, and it also fails to provide a suitable stacking of multi-radial winding layers.

[0006] A rotary transformer winding tool is known from Chinese patent CN 217484289 U. In this tool, a coil is wound around a rotary transformer. However, this rotary transformer winding tool also suffers from the aforementioned drawbacks, particularly its difficulty in manufacturing and winding, low cooling efficiency, and large space requirements.

[0007] Therefore, developing a bobbin and magnetic component that can improve upon the aforementioned conventional technology is an urgent need at present. Summary of the Invention

[0008] The object of this invention is to overcome these shortcomings. In particular, one object of this invention is to provide a spool with a compact size for supporting insulated windings, which can be efficiently cooled and allows for simple and efficient manufacturing, especially for the winding process. Furthermore, one object of this invention is to provide a magnetic component having these advantages.

[0009] Specifically, these objectives are achieved through the bobbin of the present invention. The bobbin is configured to support an insulated winding. The bobbin includes a base having an outer surface around which the winding is wound to define a winding axis. The outer surface includes at least one threaded portion helically formed along the longitudinal axis of the base, the threaded portion defining one or more thread projections and one or more thread roots. The winding of the bobbin includes a plurality of radial winding layers stacked in a radial direction perpendicular to the winding axis. Furthermore, at least one radial winding layer is inserted into at least one threaded portion.

[0010] The presence of at least one threaded portion on the spool provides ease of manufacture, particularly for the winding process using automated winding devices. Furthermore, by providing multiple radial winding layers, more portions of the winding can be cooled together, thereby improving its cooling efficiency. Moreover, since the winding is insulated, the radial winding layers can include different potentials and can, for example, be part of a primary winding and a secondary winding (for different radial winding layers).

[0011] The following directions and axes are defined above and below. In a completed or manufactured state, the winding surrounds the outer surface of the substrate of the bobbin, thus defining the winding axis, which is the axis around which the winding is wound. Specifically, the winding axis extends along the longitudinal axis of the substrate. In some embodiments, the winding axis is parallel to the longitudinal axis of the substrate. Furthermore, the radial direction is perpendicular to the winding axis. In the preceding and following text, the radial direction extends from the winding axis toward the outer surface of the substrate. In other words, the positive radial direction is defined as extending from the winding axis toward the outer surface, while the negative radial direction is defined as extending from the outer surface toward the winding axis.

[0012] Furthermore, the terms "thread protrusion" and "thread base" are used above and below. In this text, a thread protrusion refers to a protrusion in a thread (e.g., consider a screw thread), which defines the thread pitch. Furthermore, the thread base refers to the portion of a thread between adjacent protrusions. Additionally, in the preceding and following text, the threaded portion is described as helical along the longitudinal axis of the base. This term refers to a helical shape whose helical axis is along or parallel to the longitudinal axis of the base. Further, the term "following helical extension" or similar terms refer to the view along the longitudinal axis and circumferentially along the base, specifically the threaded portion.

[0013] In this respect, although a single threaded portion can be primarily defined as comprising a threaded protrusion and a threaded base (the threaded base being defined by the pitch of the threaded protrusion) that are spirally helium together, or as consisting of the aforementioned threaded protrusion and threaded base, in the foregoing and hereinafter, when following the longitudinal axis of the base, multiple threaded protrusions and threaded bases are referred to as adjacent elements in the threaded portion.

[0014] In some embodiments, the threaded base corresponds to the portion of the outer surface of the spool between the threaded protrusions. Specifically, the threaded base is flush with the outer surface (other portions). In other alternative embodiments, the threaded base is not flush with the outer surface. For example, the portion of the spool corresponding to the threaded base is thicker or wider than a portion of the spool other than at least one threaded portion. In other words, at least one threaded portion rises radially higher relative to the non-threaded portion of the spool. In some embodiments, each threaded portion rises by the same amount, or one or more (especially each) threaded portions rise by different amounts. Therefore, different portions of the spool (e.g., corresponding to windings of different types or uses) may have different (radial and / or longitudinal) dimensions, providing high flexibility of use and high cooling efficiency.

[0015] In some embodiments, a longitudinal winding layer is inserted between the two threaded protrusions of the threaded portion. In other words, the threaded portion separates two adjacent longitudinal winding layers from each other along the longitudinal axis of the substrate.

[0016] In some embodiments, the pitch of the threaded portion is equal to or greater than the cross-sectional diameter of the winding, and less than twice the cross-sectional diameter of the winding. In some embodiments, the pitch of the threaded portion is such that at most one longitudinal winding layer can be inserted between two threaded protrusions. In particular, at most one complete longitudinal winding layer can be inserted between two threaded protrusions. In other words, for example, the pitch of the threaded portion may be, for example, equal to 1.5 times the cross-sectional diameter of the winding, so that one longitudinal winding layer can be inserted between two threaded protrusions with a tolerance of half the cross-sectional diameter of the winding, and no other longitudinal winding layers are provided between the two protrusions.

[0017] In some embodiments, the outer surface includes a continuous threaded portion. In this respect, a continuous threaded portion is defined by a continuous threaded base between continuous threaded protrusions. On the other hand, in the foregoing and hereinafter, discontinuous or interrupted threaded protrusions are referred to as different threaded portions.

[0018] In some embodiments, the thread base of the threaded portion is flat or concave. This advantageously improves the ease of manufacturing the spool and cooling efficiency, while advantageously preventing damage to the windings, especially to the winding insulation.

[0019] In some embodiments, the substrate includes at least one flange at each end along its longitudinal axis. In a further embodiment, the substrate includes a flange at each end along its longitudinal axis, i.e., two flanges. This advantageously prevents the winding from slipping off the spool and thus improves ease of manufacture.

[0020] In some embodiments, the outer surface of the substrate includes at least one unthreaded portion at the end of the threaded portion along the longitudinal axis. Thus, for example, the bobbin is provided with a transition portion as at least one unthreaded portion. This improves ease and efficiency of manufacturing, particularly for the winding process. Specifically, in cases where the substrate includes at least one flange and at least one unthreaded portion located at the flange, the unthreaded portion advantageously prevents positioning errors when the winding is wound around the substrate.

[0021] In some embodiments, where the substrate includes at least one flange and at least one unthreaded portion located at the end (i.e., at the flange), at least two longitudinal winding layers are inserted into a corresponding unthreaded portion. These at least two longitudinal layers are in contact with each other. In some embodiments, more than two longitudinal layers are inserted into a corresponding unthreaded portion. For example, three or more, four or more, five or more longitudinal layers are inserted into a corresponding unthreaded portion.

[0022] Furthermore, the spool includes multiple (e.g., two) such unthreaded portions, particularly at each end of the threaded portion along the longitudinal axis. In other words, according to some embodiments, the spool includes two unthreaded portions and one threaded portion, the threaded portion being arranged between the unthreaded portions along the longitudinal axis. Flanges are respectively arranged at the ends of each of the two unthreaded portions. Therefore, ease and efficiency of manufacture are advantageously improved.

[0023] In a further embodiment, at least one radial winding layer is radially stacked on at least one threaded protrusion of the threaded portion. This achieves an advantageous, compact, and space-saving positioning of the winding layers, thereby also improving their cooling efficiency.

[0024] In some embodiments, the pitch of the threaded portion is maintained constant along the longitudinal axis of the base. In other words, the distance between two adjacent threaded protrusions is substantially constant when following its helical shape along the longitudinal axis of the base. In this respect, "constant" means that the pitch is fixed within manufacturing tolerances, for example, within ±10%. The constant pitch of the threaded portion has the advantage of simplifying the winding process, thereby providing ease and efficiency in manufacturing.

[0025] In some embodiments, the cross-sectional shape of the threaded protrusion, which is parallel to the longitudinal axis, remains fixed along the helical extension of the threaded portion. In other words, the cross-sectional shape of the threaded protrusion remains fixed along the longitudinal axis and in the circumferential direction of the base (i.e., as it extends helically along the threaded portion). Therefore, the manufacturing process of the spool is simplified, particularly the manufacturing process of the spool base including the threaded portion.

[0026] In some embodiments, the cross-sectional shape of the threaded protrusion, which is parallel to the longitudinal axis, varies along the helical extension of the threaded portion. In other words, the cross-sectional shape of the threaded protrusion is not fixed along the helical extension of the threaded portion. Therefore, the geometry of the threaded portion advantageously increases manufacturing ease (particularly for the winding process) and / or reduces winding slippage. Furthermore, the varying cross-sectional shape of the threaded protrusion advantageously provides guidance on which portions of the base should provide more or less winding, thereby increasing manufacturing ease.

[0027] In some embodiments, the cross-sectional shape of the threaded protrusion gradually decreases towards at least one end of the threaded protrusion as it extends helically along the threaded portion. In other words, along the longitudinal axis, its cross-sectional shape gradually decreases towards at least one end of the threaded protrusion as it follows the helium extension of the threaded portion. In some embodiments, the cross-sectional shape of the threaded protrusion gradually decreases towards both ends of the threaded protrusion. Thus, the reduced end of the threaded portion advantageously provides a transition between the unthreaded and threaded portions of the base. Consequently, misalignment or positioning problems during winding are advantageously prevented or reduced. Furthermore, this reduced end of the threaded portion advantageously prevents damage to the winding by reducing the number of sharp edges of the threaded portion.

[0028] In some embodiments, the winding includes a first winding portion and a second winding portion that are electrically insulated from each other. In other words, the first winding portion and the second winding portion are not directly electrically connected to each other. Here, the induced current induced in one (first) winding portion in another (second) winding portion (e.g., in the example case of a transformer) falls under the definition of "electrically insulated from each other".

[0029] In some embodiments, as described above, only the radial winding layer of the first winding portion of the winding is inserted into the threaded portion. In other words, the windings of the second winding portion or other winding portions besides the first winding portion are not inserted into the threaded portion. In some embodiments where the bobbin includes multiple threaded portions, each such threaded portion inserts only the winding of one winding portion described above. For example, the first threaded portion includes only the winding of the first winding portion, and the second threaded portion includes only the winding of the second winding portion.

[0030] In some embodiments, only the radial winding layers of the second winding portion of the winding are radially stacked on at least one threaded protrusion of the threaded portion. For example, the winding of the first winding portion is inserted into the threaded portion. The winding of the second winding portion is radially stacked on at least one threaded protrusion of the threaded portion. In some embodiments, the winding of the second winding portion is not radially stacked on the winding of the first winding portion. In some embodiments, additional radial winding layers of the first winding portion are radially stacked on the winding inserted in the threaded portion of the first winding portion.

[0031] Furthermore, in some embodiments, the first winding portion and the second winding portion are at least partially arranged in a double-wire configuration. Therefore, especially when the winding process is involved, ease and efficiency in manufacturing are advantageously achieved.

[0032] In some embodiments, in a bi-threaded arrangement, in the first radial winding layer, the first winding portion is inserted into the threaded portion; in at least one additional radial winding layer, the first and second winding portions are arranged in a bi-threaded configuration such that the second winding portion is radially stacked on the threaded protrusion, and the first winding portion is radially stacked on the first winding portion of the first radial winding layer. In some embodiments, the pitch of the threaded portion and the dimensions of the threaded protrusion and thread base correspond to the cross-sectional diameter of the windings of the first and second winding portions. The cross-sectional width of the threaded protrusion, parallel to the longitudinal axis, is equal to the cross-sectional diameter of the windings of the first and / or second winding portions, particularly equal to the cross-sectional diameter of all winding portions of the winding. Therefore, ease and efficiency in manufacturing, as well as advantageous cooling efficiency, are achieved.

[0033] In some embodiments, the spool includes a plurality of bases. In some embodiments, the plurality of bases are integrally formed with each other. Further, each of the plurality of bases includes a separate winding. In some embodiments, a winding wound around one base is connected in series with a winding wound around another base of the same spool, only in series with one or more portions of its winding.

[0034] The present invention also relates to a magnetic component. The magnetic component includes at least one spool according to any of the embodiments and examples described above.

[0035] In some embodiments, the magnetic component includes a transformer and / or a choke. In an example of a magnetic component including a transformer, a first winding portion is part of the transformer's primary winding, and a second winding portion is part of the transformer's secondary winding. Thus, a magnetic component, particularly a transformer, with a compact and space-saving shape and high cooling efficiency is achieved, which can also be manufactured easily and efficiently, especially for the winding process.

[0036] In some embodiments, the magnetic component includes a plurality of spools, each spool forming a portion of a phase of a multiphase transformer. For example, the magnetic component includes a three-phase transformer and three corresponding spools, each spool forming a portion of a phase of the transformer. Additional spools may form a portion of one or more chokes.

[0037] The above embodiments and configurations can be combined with each other. Simple Explanation of the Diagram

[0038] Figure 1 shows a schematic side view of a spool according to a first embodiment of the present invention; Figure 2 shows a perspective view of a spool according to a first embodiment of the present invention; Figure 3 shows a cross-sectional view of a spool according to a first embodiment of the present invention; Figure 4 shows a schematic side view of a spool according to a second embodiment of the present invention; Figure 5 shows a perspective view of a spool according to a second embodiment of the present invention; Figure 6 shows a cross-sectional view of a spool according to a second embodiment of the present invention; Figure 7 shows a schematic side view of a spool according to a third embodiment of the present invention; Figure 8 shows a perspective view of a spool according to a third embodiment of the present invention; Figure 9 shows a cross-sectional view of a spool according to a third embodiment of the present invention; Figure 10 shows a perspective view of a spool according to a fourth embodiment of the present invention; and Figure 11 shows a schematic diagram of a magnetic component according to a fifth embodiment of the present invention. Implementation

[0039] Some typical embodiments that embody the features and advantages of this case will be described in detail in the following description. It should be understood that this case can have various variations in different forms, all of which do not depart from the scope of this case, and the descriptions and illustrations therein are essentially for illustrative purposes and not intended to limit this case.

[0040] The first embodiment of the present invention will now be described with reference to Figures 1 through 3. Figure 1 shows a schematic side view of a spool 1 according to the first embodiment of the present invention, Figure 2 shows a perspective view of a spool 1 according to the first embodiment of the present invention, and Figure 3 shows a cross-sectional view of a spool 1 according to the first embodiment of the present invention.

[0041] Specifically, for ease of explanation of the spool 1, the insulated winding 2 of the spool 1 in this embodiment is omitted in Figures 1 and 2 (it will be discussed specifically with reference to Figure 3). In other words, Figures 1 and 2 specifically show the state of the spool 1 before the winding 2 is wound, while Figure 3 shows the state of the spool 1 after it is wound with the winding 2. Furthermore, Figure 3 shows a radial half of the spool 1 for illustrative purposes.

[0042] The bobbin 1 includes a base 3 and an insulated winding 2. The base 3 includes an outer surface 4, around which the winding 2 is wound (see Figure 3).

[0043] In this embodiment, the outer surface 4 includes a threaded portion 6. As shown in Figures 1 and 2, the threaded portion 6 is helical along the longitudinal axis 7 of the base 3. The threaded portion 6 defines a threaded protrusion 6.1 and a threaded base 6.2.

[0044] The threaded protrusion 6.1 protrudes from the outer surface 4 in the radial direction 12. The threaded base 6.2 corresponds to the outer surface 4 of the base 3 between the threaded protrusions 6.1. In other words, as shown in Figures 1 and 2, the threaded base 6.2 is flush with the outer surface 4 at the non-threaded portion 13.

[0045] In this embodiment, the thread base 6.2 is flat. In an alternative embodiment, the thread base 6.2 is concave in the radial direction 12, thereby allowing the winding 2 to fit more tightly. The concave or flat configuration of the thread base 6.2 allows the winding 2 to fit tightly while preventing damage to it during winding, such as preventing insulation damage.

[0046] In this embodiment, the pitch 8 of the threaded portion 6 is defined as the distance between the two threaded protrusions 6.1 along the longitudinal axis 7, and the pitch 8 is kept fixed along the longitudinal axis 7.

[0047] Furthermore, in this example, the cross-sectional shape of the threaded protrusion 6.1, which is parallel to the longitudinal axis 7, remains fixed along the helical extension of the threaded portion 6. Here, the cross-sectional shape plane refers to, for example, the plane defined by the longitudinal axis 7 and the extension in the radial direction 12. In Figure 1, the upper left end 23 of the threaded portion 6 shows this cross-sectional shape, which is rectangular in this case.

[0048] In this embodiment, the base 3 includes two flanges 10, each located at one end 11 of the base along its longitudinal axis 7.

[0049] As shown in Figure 2, each of the two flanges 10 includes a winding guide portion 24 for guiding the winding 2 from the spool 1 to the spool 1.

[0050] The insulated winding 2 of the bobbin 1 in this embodiment will now be described with reference to Figure 3. In some embodiments, the insulated winding 2 is wound around the bobbin 1 using a winding process such as automatic winding. The winding 2 defines a winding axis 5 around which its winding is enclosed. In this embodiment, the winding axis 5 is parallel to the longitudinal axis 7. In particular, in this embodiment, the winding axis 5 is coaxial with the longitudinal axis 7.

[0051] Winding 2 includes multiple (exactly three in this example) radial winding layers 2.1–2.3. The radial winding layers 2.1–2.3 are stacked in the radial direction 12. In this embodiment, the radial winding layers 2.1–2.3 are stacked perpendicular to the winding axis 5.

[0052] In addition, a radial winding layer 2.1 is inserted into the threaded portion 6. Specifically, only one radial winding layer 2.1 is inserted into the threaded portion 6.

[0053] In addition, winding 2 includes multiple (exactly ten in this example) longitudinal layers 2.4–2.13.

[0054] The pitch 8 of the threaded portion 6 is equal to or greater than the cross-sectional diameter 9 of the winding 2 (corresponding to the cross-sectional shape described above), and less than twice the cross-sectional diameter 9 of the winding 2. In other words, only one longitudinal layer 2.4–2.13 is inserted between the two threaded protrusions 6.1 of the threaded portion 6. It should be noted that the pitch 8, by definition, includes the two halves of the corresponding threaded protrusion 6.1 (between which the pitch 8 is defined).

[0055] In the alternative definition above, the distance between the two threaded protrusions 6.1, that is, the width of the thread base 6.2 along the longitudinal axis 7, is approximately equal to the cross-sectional diameter 9 of the winding 2.

[0056] Furthermore, only one longitudinal layer 2.4 and only one radial winding layer 2.1 are inserted between the two threaded protrusions 6.1 of the threaded portion 6. In other words, the cross-sectional height 25 of the threaded protrusion 6.1 in the radial direction 12 is approximately equal to the cross-sectional diameter 9 of the winding 2.

[0057] As shown in Figures 1 and 3 and as described above, the base 3 includes a flange 10 and at least one unthreaded portion 13 located at end 11 (i.e., at flange 10). At least two longitudinal layers 2.12 and 2.13 of the winding 2 are inserted into the unthreaded portion 13 between flange 10 and the first threaded protrusion 6.1 of threaded portion 6. These two longitudinal layers 2.12 and 2.13 are in contact with each other. This will now be described in more detail. At the other end 11, a longitudinal layer 2.4 is provided between flange 10 and (the last or fourth) threaded protrusion 6.1.

[0058] As indicated by different shades in Figure 3, in this embodiment, winding 2 includes a first winding portion 21 and a second winding portion 22 that are electrically insulated from each other. In other words, the first winding portion 21 and the second winding portion 22 are not directly electrically connected to each other. As will be explained with reference to Figure 11, the first winding portion 21 and the second winding portion 22 can be, for example, a primary winding and a secondary winding, or, for example, a choke winding and a primary or secondary winding, etc.

[0059] Here, the virtual line 26 shown indicates that the first winding portion 21 and the second winding portion 22 are arranged in a double-line configuration, that is, they are wound together around the base 3. However, this is not mandatory; the first winding portion 21 and the second winding portion 22 can also be wound separately around the base 3.

[0060] Furthermore, only the radial winding layers 2.1–2.3 of the first winding portion 21 are inserted between the threaded protrusions 6.1. In particular, only one radial winding layer 2.1 and only one longitudinal layer 2.6, 2.8 and 2.10 of the first winding portion 21 are inserted on the threaded base 6.2 between the threaded protrusions 6.1.

[0061] Only the radial winding layers 2.2 and 2.3 of the second winding portion 22 are radially stacked on the threaded protrusion 6.1 of the threaded portion 6. On the other hand, only the radial winding layers 2.2 and 2.3 of the first winding portion 21 are radially stacked on the first radial winding layer 2.1 of the first winding portion 21. In the non-threaded portion 13, the radial winding layers 2.1, 2.2, and 2.3 of the first winding portion 21 and the second winding portion 22, and in particular all these radial winding layers, are stacked on the outer surface 4 of the base 3.

[0062] It should be noted that the total number of radial winding layers 2.1–2.3 and / or the total number of longitudinal winding layers 2.4–2.13 are generally not limited to those described in the embodiments. In particular, it should be noted that the number of winding layers (especially their total number of turns) is variable, especially for the specific application of spool 1.

[0063] The winding process will now be described with respect to the first winding portion 21 and the second winding portion 22 and their bi-wire arrangement.

[0064] In Figure 3, the beginning of the first winding portion 21 is indicated by reference numeral 27. Furthermore, the beginning of the second winding portion 22 is indicated by reference numeral 28. The end of the first winding portion 21 is indicated by reference numeral 29, and the end of the second winding portion 22 is indicated by reference numeral 30.

[0065] This indicates that the winding process begins with the provision of a first winding portion 21 in the threaded portion 6 (left side of Figure 3). At the end of the first pass (indicated by the start 28 of the second winding portion 22) along the longitudinal axis 7, the first winding portion 21 and the second winding portion 22 then begin a second pass with a double-wire arrangement. Therefore, each radial winding layer 2.1–2.3 is formed by winding the winding portions 21 and 22 once along the longitudinal axis 7. In other words, the winding process begins on the left side of Figure 3, proceeds to the right to form the first radial winding layer 2.1, then (at the top of the threaded portion 6) returns to the left to form the second radial winding layer 2.2, and then (at the top of the second radial winding layer 2.2) returns to the right to form the third and final radial winding layer 2.3. Thus, in this example, the first winding portion 21 has more turns than the second winding portion 22.

[0066] By providing this arrangement, the following exemplary advantages are achieved. First, by radially stacking the windings 2 as shown, particularly stacking the second winding portion 22 on the threaded protrusion 6.1, a significant reduction in air-fill space is achieved compared to the case where no threaded portion 6 is provided, i.e., compared to the case where the outer surface 4 of the spool 1 is flat in cross-section. This greatly improves cooling efficiency when cooling the windings 2. Furthermore, this spool 1 provides a highly efficient winding process because, for example, the number of turns of each winding portion 21 and 22 can be easily predetermined, particularly by the pitch 8 and / or the number and / or length of the threaded portion 6.

[0067] However, it should be noted that the winding process described herein and the results shown in Figure 3 are ideal. In practical applications, some of the upper radial winding layers 2.2–2.3 may slip, causing certain portions of the second winding portion 22 (at least partially) to lie on certain portions of the first winding portion 21, and vice versa, or certain portions of the first winding portion 21 (at least partially) to lie on the protrusions 6.1. On the other hand, the likelihood of this occurring is reduced thanks to the advantageous configuration of the threaded portion 6. Furthermore, even in this case, thanks to the threaded portion 6, the first winding portion 21 is securely held between the threaded protrusions 6.1.

[0068] The second embodiment of the present invention will now be described with reference to Figures 4 through 6. Figure 4 shows a schematic side view of a spool 1 according to the second embodiment of the present invention, Figure 5 shows a perspective view of a spool 1 according to the second embodiment of the present invention, and Figure 6 shows a cross-sectional view of a spool 1 according to the second embodiment of the present invention.

[0069] Similar to Figures 1 through 3, Figures 4 and 5 of this embodiment omit the winding 2 for ease of explanation, while Figure 6 shows the winding state of the bobbin 1. Here, Figure 6 shows two radial halves of the bobbin 1 (i.e., a complete cross-sectional view). Furthermore, Figure 6 also shows two exemplary magnetic cores 31 inserted into the bobbin 1.

[0070] In this embodiment, the spool 1 includes two non-threaded portions 13, each located at one end 11 of the base 3 along the longitudinal axis 7.

[0071] Between the two non-threaded portions 13, the spool 1 includes a threaded portion 6. Here, the threaded portion 6 includes a single thread, namely two threaded protrusions 6.1 and a threaded base 6.2. Along the longitudinal axis 7, the threaded portion 6 and the two non-threaded portions 13 each occupy approximately one-third of the length of the base 3.

[0072] Here, the cross-sectional shape of the threaded protrusion 6.1 in a plane parallel to the longitudinal axis 7 (e.g., in the plane of the radial direction 12 and the longitudinal axis 7) varies along the helical extension of the threaded portion 6. In particular, this cross-sectional shape varies gradually and continuously along the helical extension of the threaded portion 6.

[0073] Specifically, the cross-sectional shape of the threaded protrusion 6.1 gradually decreases towards the end 14 of the threaded protrusion 6.1. Therefore, during the winding process, damage to the winding 2, especially damage to its insulation, can be prevented or reduced.

[0074] Now, referring to Figure 6, the winding 2 of the bobbin 1 in this embodiment is described.

[0075] As the threaded protrusion 6.1 gradually decreases in size, as shown in Figure 6, the threaded portion 6 in this embodiment continuously includes a thick threaded protrusion 33 and two thin threaded protrusions 34 along the circumferential direction 35 of the base 3, which is perpendicular to the radial direction 12 and the longitudinal axis 7.

[0076] In this embodiment, the two thin threaded protrusions 34 are defined as portions of the threaded portion 6 along the circumferential direction 35, wherein the cross-sectional width 37 of the threaded protrusion 6.1 is smaller than the cross-sectional width 9 of the winding 2. The other portions of the threaded portion 6 along the circumferential direction 35 are defined as thick threaded protrusions 33, wherein the cross-sectional width 37 is equal to or greater than the cross-sectional width 9 of the winding 2.

[0077] Here, the pitch 8, defined by the distance between the midpoints of the threaded protrusions 6.1 along the longitudinal axis 7, is fixed where two adjacent threaded protrusions 6.1 exist. In other words, the width of the thread base 6.2 along the longitudinal axis 7 is fixed as it extends helically.

[0078] Here, for example, only one winding portion 21 is provided. However, this embodiment can be suitably combined with the above embodiments to provide two winding portions 21 and 22.

[0079] In this embodiment, only one radial winding layer 2.1 of winding 2 is inserted into the threaded portion 6 between the two threaded protrusions 6.1, that is, between the two thin threaded protrusions 34. As described above, the cross-sectional shape of the threaded protrusion 6.1 varies along the helical extension of the threaded portion 6. Here, the maximum cross-sectional width 37 of the threaded protrusion 6.1 (i.e., the thick threaded protrusion 33) is equal to or greater than the cross-sectional width 9 of winding 2, for example, approximately twice the cross-sectional width 9 of winding 2. Therefore, the two longitudinal winding layers 2.8 and 2.9 of winding 2 are radially stacked on the threaded protrusion 6.1.

[0080] It should be noted that the asymmetrical winding configuration shown in Figure 6 (the upper half is obviously more wound than the lower half) is only due to the cross-section of the spool 1 shown. After all the turns of a single radial winding layer (e.g., radial winding layer 2.1) are completed, winding 2 is moved to the "next" radial winding layer (e.g., radial winding layer 2.2), making the winding appear asymmetrical in that cross-section.

[0081] In this embodiment, two magnetic cores 31 are inserted into the spool 1. Typically, an air gap 32 is provided between the two magnetic cores 31 along the longitudinal axis 7 to set the inductance value. As shown in Figure 6, an edge magnetic field 36 is generated at the air gap 32.

[0082] In this embodiment, the threaded portion 6 is configured such that the winding 2 is at least partially moved along the longitudinal axis 7 away from the air gap 32. Therefore, the influence of the edge magnetic field 36 on the winding 2 is reduced, thereby also reducing its AC resistance. Furthermore, manufacturing is simplified because the winding 2 can be easily inserted into the threaded portion 6, especially through an automated winding process. In addition, the fill factor (i.e., the ratio of the space filled by the winding to the space filled by the air in the spool 1) remains high, which advantageously improves the cooling efficiency and overall size of the spool 1.

[0083] The third embodiment of the present invention will now be described with reference to Figures 7 through 9. Figure 7 shows a schematic side view of a spool 1 according to the third embodiment of the present invention, Figure 8 shows a perspective view of a spool 1 according to the third embodiment of the present invention, and Figure 9 shows a cross-sectional view of a spool 1 according to the third embodiment of the present invention.

[0084] Similar to some parts of the above embodiments, in Figures 7 and 8, the winding 2 is omitted for ease of explanation of the base 3.

[0085] In this embodiment, similar to the second embodiment, the cross-sectional shape of the threaded protrusion 6.1 varies along the helical extension of the threaded portion 6. In particular, the threaded protrusion 6.1 gradually decreases in size along the longitudinal axis 7 toward its end 14. Here, along the longitudinal axis 7, both non-threaded portions 13 comprise approximately one-quarter of the length of the base 3, while the threaded portion 6 comprises approximately half the length of the base 3.

[0086] As shown in Figure 9, in this embodiment, the spool 1 includes three magnetic cores 31, and two air gaps 32 are formed between two adjacent magnetic cores 31 along the longitudinal axis 7.

[0087] Similar to the second embodiment, in this embodiment, the AC resistance of the winding 2 is reduced by moving the winding 2 away from the edge magnetic field 36 at the air gap 32. Therefore, as shown in the comparison results of Figures 6 and 9, the threaded portion 6 in this embodiment has a longer length along the longitudinal axis 7. Furthermore, by placing the winding 2 within the threaded portion 6, the fill factor is advantageously kept high, thereby improving cooling and reducing the space required for the spool 1.

[0088] In some embodiments, the number of threaded portions 6 corresponds to the number of air gaps 32 formed between adjacent magnetic cores 31. In other words, if n air gaps 32 are provided, n threaded portions 6 are also provided. In this respect, a single threaded portion 6 is defined as a continuous threaded portion 6. In particular, multiple threaded portions 6 are separated by non-threaded portions 13 between them.

[0089] Furthermore, in some embodiments, each threaded portion 6 is located radially outside each air gap 32. For example, if the air gap 32 is located at the end 11 of the spool 1, then the threaded portion 6 is also located at the end 11 of the spool 1.

[0090] Compared to, for example, providing a portion at the air gap 32 where there is strictly no winding 2, the advantage of this embodiment is that the winding process is more efficient, especially since it can be easily automated, particularly because a continuous winding process can be used.

[0091] Figure 10 shows a perspective view of a spool 1 according to a fourth embodiment of the present invention.

[0092] In this embodiment, the spool 1 includes multiple substrates 3.1 and 3.2, namely a first substrate 3.1 and a second substrate 3.2. In some embodiments, the multiple substrates 3.1 and 3.2 are integrally formed with each other.

[0093] Here, each of the bases 3.1 and 3.2 includes a winding (not shown). The windings of bases 3.1 and 3.2 may be separate from each other, i.e., insulated from each other, or they may be connected to each other, especially in series. For example, in one case, the winding wound around one base 3.1 is a choke winding, while the winding wound around the other base 3.2 is a primary or secondary winding. In particular, the winding of one base 3.1 is connected in series with a winding portion of the other base 3.2 (e.g., the first winding portion 21 described above).

[0094] Furthermore, in some embodiments, one or all of the plurality of bases 3.1 and 3.2 include threaded portions 6.

[0095] Figure 11 shows a schematic diagram of a magnetic component 100 according to a fifth embodiment of the present invention.

[0096] The magnetic component 100 in this embodiment includes three spools 1 according to any of the above embodiments. In particular, the magnetic component 100 shown in Figure 11 includes three spools 1 according to the fourth embodiment, wherein each spool 1 includes a first substrate 3.1 and a second substrate 3.2.

[0097] In this embodiment, the magnetic component 100 includes a three-phase transformer 101 formed by windings 2 and a magnetic core 31 (not visible in Figure 11). Here, the aforementioned first winding portion 21 of each spool 1 forms the primary winding of the transformer 101, and the aforementioned second winding portion 22 of each spool 1 forms the secondary winding of the transformer 101, wherein each spool 1 is part of a phase of the three-phase transformer 101. In this example, the first base 3.1 forms the choke of the three-phase transformer 101. In some embodiments, the windings 2 of the base 3.1 are connected in series with the first winding portion 21 of each respective spool 1.

[0098] Through the above embodiments, this application provides a bobbin 1 that advantageously saves space while allowing for simple and efficient manufacturing and cooling. Furthermore, the above embodiments provide a magnetic component 100, particularly a transformer 101, that possesses these advantages.

[0099] In addition to the above textual description, please refer to Figures 1 through 11, which show in detail configuration examples of this application.

[0100] It should be noted that the above are merely preferred embodiments for illustrative purposes, and the scope of this application is not limited to the described embodiments. The scope of this application is determined by the claims of the appended patent application. Furthermore, this application may be modified in various ways by those skilled in the art, but all such modifications shall not depart from the protection sought by the claims of the appended patent application.

[0101] 1: Bollard 2: Winding 2.1, 2.2, 2.3: Radial winding layers 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 2.10, 2.11, 2.12, 2.13: Longitudinal winding layers 3: Matrix 3.1: First matrix 3.2: Second matrix 4: Outer surface 5: Winding axis 6: Threaded part 6.1: Threaded protrusion 6.2: Thread base 7: Longitudinal axis 8: Pitch 9: Cross-sectional diameter 10: Flange 11: End 12: Radial direction 13: Non-threaded part 14:End 21: First winding section 22: Second winding section 23: Upper left end of the threaded section 24: Winding Guide Section 25: Cross-sectional height 26: Virtual Line 27: The beginning of the first winding section 28: The beginning of the second winding section 29: End of the first winding section 30: End of the second winding section 31: Magnetic core 32: Air gap 33: Thick thread protrusion 34: Thin thread protrusion 35: Circumferential direction 36: Edge magnetic field 37: Cross-sectional width 100: Magnetic components 101: Transformer

Claims

1. A bobbin for supporting an insulated winding, comprising: A substrate having an outer surface around which the winding is wound to define the winding axis; The outer surface includes at least one threaded portion that is helically oriented along the longitudinal axis of the substrate, the threaded portion defining one or more threaded protrusions and threaded bases; the winding includes a plurality of radial winding layers stacked in a radial direction perpendicular to the winding axis, and at least one radial winding layer is inserted into the at least one threaded portion.

2. The spool of claim 1, wherein a longitudinal winding layer of the winding is inserted between two threaded protrusions of the threaded portion.

3. The bobbin of claim 2, wherein the pitch of the threaded portion is equal to or greater than the cross-sectional diameter of the winding, and less than twice the cross-sectional diameter of the winding.

4. The spool of claim 1, wherein the outer surface of the base includes at least one non-threaded portion at the end of the threaded portion along the longitudinal axis.

5. The bobbin as requested in item 4, wherein at least two longitudinal winding layers of the winding are inserted into a corresponding non-threaded portion.

6. The spool of claim 1, wherein at least one radial winding layer is radially stacked on at least one threaded protrusion of the threaded portion.

7. The spool of claim 1, wherein the pitch of the threaded portion remains fixed along the longitudinal axis of the base.

8. The spool of claim 1, wherein the cross-sectional shape of the threaded protrusion, which is parallel to the longitudinal axis, remains fixed along the helical extension of the threaded portion or gradually decreases toward at least one end of the threaded protrusion.

9. The spool of claim 1, wherein the winding comprises a first winding portion and a second winding portion that are electrically insulated from each other.

10. The spool of claim 9, wherein only the radial winding layer of the first winding portion of the winding is inserted into the threaded portion.

11. The spool of claim 10, wherein only the radial winding layer of the second winding portion of the winding is radially stacked on at least one threaded protrusion of the threaded portion.

12. The spool of claim 11, wherein the first winding portion and the second winding portion are at least partially arranged in a double-wire configuration.

13. The spool of claim 12, wherein in a first radial winding layer, the first winding portion is inserted into the threaded portion; and in at least one additional radial winding layer, the first winding portion and the second winding portion are arranged in a double-wire arrangement such that the second winding portion is radially stacked on the threaded protrusion and the first winding portion is radially stacked on the first winding portion of the first radial winding layer.

14. A magnetic component comprising at least one spool as claimed in claim 1.

15. The magnetic component of claim 14, wherein the winding comprises a first winding portion and a second winding portion electrically insulated from each other; wherein the magnetic component comprises a transformer, the first winding portion being part of the primary winding of the transformer, and the second winding portion being part of the secondary winding of the transformer.

Images