The present invention relates to a conductive winding module, and more particularly to a conductive winding module by continuously winding multiple loops of coils. The present invention also relates to a transformer having such a conductive winding module.
A transformer has become an essential electronic component for voltage regulation into required voltages for various kinds of electric appliances. Referring to
The conductive piece 12 of the transformer 1 is a one-loop structure. Although the one-loop conductive piece 12 may reduce the overall volume of the transformer 1, there are still some drawbacks. For example, the process of winding the coil is complicated because the conductive pieces 12 need to be accommodated within the guiding slots 107. In addition, the system board should have corresponding trace pattern for making electrical connection between these two conductive pieces 12. As a consequence, the power loss is increased and the components of the transformer are increased. Under this circumstance, the circuitry of the system board becomes more complicated.
In views of the above-described disadvantages resulted from the conventional method, the applicant keeps on carving unflaggingly to develop a conductive winding module and a transformer having such a conductive winding module.
It is an object of the present invention to provide a conductive winding module by continuously winding multiple loops of coils.
Another object of the present invention provides a conductive winding module for increasing the power density without considerably increasing the overall volume.
A further object of the present invention provides a transformer having such a conductive winding module, in which the transformer is suitable for mass production.
In accordance with an aspect of the present invention, there is provided a conductive winding module for use in a magnetic element. The conductive winding module includes a plurality of conductive parts and at least one connecting part. Each of the conductive parts includes a conductive body, a first terminal and a second terminal. The conductive body is interconnected between the first terminal and the second terminal and having a hollow portion therein. The connecting part has a first end and a second end for interconnecting any two adjacent conductive parts. A first connecting line is defined between the first end of the connecting part and the first terminal of an adjacent conductive part. A second connecting line is defined between the second end of the connecting part and the second terminal of an adjacent conductive part. The conductive parts are folded with respect to the first connecting line and the second connecting line such that the first hollow portions of the conductive parts are aligned with each other to define a through-hole.
In accordance with another aspect of the present invention, there is provided a transformer. The transformer includes a winding coil, a conductive winding module and a magnetic core assembly. The conductive winding module includes a plurality of conductive parts and at least one connecting part. Each of the conductive parts includes a conductive body, a first terminal and a second terminal. The conductive body is interconnected between the first terminal and the second terminal and having a hollow portion therein. The connecting part has a first end and a second end for interconnecting any two adjacent conductive parts. A first connecting line is defined between the first end of the connecting part and the first terminal of an adjacent conductive part. A second connecting line is defined between the second end of the connecting part and the second terminal of an adjacent conductive part. The conductive parts are folded with respect to the first connecting line and the second connecting line such that the first hollow portions of the conductive parts are aligned with each other to define a through-hole. The magnetic core assembly is partially embedded into the winding coil and the through-hole of the conductive winding module.
In accordance with a further aspect of the present invention, there is provided a transformer. The transformer includes a circuit board, a conductive winding module and a magnetic core assembly. The circuit board has a trace pattern of a primary winding coil and a first through-hole. The conductive winding module includes a plurality of conductive parts and at least one connecting part. Each of the conductive parts includes a conductive body, a first terminal and a second terminal. The conductive body is interconnected between the first terminal and the second terminal and having a hollow portion therein. The connecting part has a first end and a second end for interconnecting any two adjacent conductive parts. A first connecting line is defined between the first end of the connecting part and the first terminal of an adjacent conductive part. A second connecting line is defined between the second end of the connecting part and the second terminal of an adjacent conductive part. The conductive parts are folded with respect to the first connecting line and the second connecting line such that the first hollow portions of the conductive parts are aligned with each other to define a second through-hole. The magnetic core assembly is partially embedded into the first through-hole of the circuit board and the second through-hole of the conductive winding module.
The above contents of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
a) is a schematic view illustrating a conductive winding module according to a first preferred embodiment of the present invention;
b) is a schematic perspective view of the folded conductive winding module of
a) is a schematic view illustrating a conductive winding module according to a second preferred embodiment of the present invention;
b) is a schematic perspective view of the folded conductive winding module of
a) is a schematic view illustrating a conductive winding module according to a third preferred embodiment of the present invention;
b) is a schematic perspective view of the folded conductive winding module of
The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed.
a) is a schematic view illustrating a conductive winding module according to a first preferred embodiment of the present invention. The conductive winding module 22 is a single conductive piece made of metallic material such as copper. The conductive winding module 22 principally includes a plurality of conductive parts 221, a plurality of connecting parts 222 and pins 223. In this embodiment, three conductive parts 221 are included in the conductive winding module 22 for illustration. Every two adjacent conductive parts 221 are interconnected by a connecting part 222. Similarly, each pin 223 is coupled to the adjacent conductive part 221 through a connecting part 222.
Every conductive part 221 principally includes a conductive body 2211, a first terminal 2212, a second terminal 2213, a first surface 2216 and a second surface 2217. In this embodiment, the conductive body 2211 is ring-shaped and has a notch 2215 between the first terminal 2212 and the second terminal 2213. In addition, a hollow portion 2214 is formed in the center of the conductive body 2211. The second surface 2217 is opposed to the first surface 2216 for each conductive part 221. For example, the first surfaces 2216 of these conductive parts 221 face upwardly but the second surfaces 2217 thereof face downwardly.
Every connecting part 222 has a first end 2221 and a second end 2222. A first connecting line 224 is defined between the first end 2221 of the connecting part 222 and the first terminal 2212 of the adjacent conductive part 221. A second connecting line 225 is defined between the second end 2222 of the connecting part 222 and the second terminal 2213 of the adjacent conductive part 221. Likewise, the first side 2223 and the second side 2224 are respectively coplanar with the first surfaces 2216 and the second surfaces 2217 of the conductive parts 221.
By using the first connecting line 224 and the second connecting line 225 as bending lines, the first ends 2221 of the connecting parts 222 are bent in the direction A and the second ends 2222 of the connecting parts 222 are bent in the direction B. Then, these conductive parts 221 are folded with respect to the first connecting line 224 and the second connecting line 225 such that small acute angles are formed between the first side 2223 of a connecting part 222 and the first surface 2216 of an adjacent conductive part 221 and between the second side 2224 of a connecting part 222 and the second surface 2217 of an adjacent conductive part 221. The resulting structure of the folded conductive winding module is schematically shown in
a) is a schematic view illustrating a conductive winding module according to a second preferred embodiment of the present invention. The conductive winding module 32 is also a single conductive piece made of metallic material such as copper. The conductive winding module 32 principally includes a first winding unit 328 and at least an extension part 326. The first winding unit 328 may be used as the secondary winding coil of a transformer for example. The first winding unit 328 includes a plurality of conductive parts 321 and a plurality of connecting parts 322. Every two adjacent conductive parts 321 are interconnected by a connecting part 322. By using the similar folding process as described in
In addition, two extension parts 326 are respectively coupled to a first side 3212 and a second side 3213 of the first winding unit 328. Each of the extension parts 326 has several holes 3261 and several pins 3262. In some embodiments, an electronic component such as a transistor may be fixed on the extension part 326 such that the extension part 326 functions as a heat sink. By penetrating for example screws (not shown) through the holes 3261 and then coupled with corresponding nuts (not shown), the electronic component may be fixed on the extension part 326. The pins 3262 may be bonded on a system board (not shown).
Please refer to
b) is a schematic perspective view illustrating arrangement of the conductive winding module of
It is noted that, however, those skilled in the art will readily observe that numerous modifications and alterations may be made while retaining the teachings of the invention. For example, the conductive winding module of the present invention may be an unbroken conductive piece having more than three loops. In addition, the conductive body of the conductive part of the conductive winding module may have an arbitrary shape such as a rectangular shape or a polygonal shape.
a) is a schematic view illustrating a conductive winding module according to a second preferred embodiment of the present invention. The conductive winding module 32 is also a single conductive piece made of metallic material such as copper. The conductive winding module 32 principally includes a first winding unit 328, an extension part 326 and a pin 323. The first winding unit 328 may be used as the secondary winding coil of a transformer for example. The first winding unit 328 includes a plurality of conductive parts 321 and a plurality of connecting parts 322. Every two adjacent conductive parts 321 are interconnected by a connecting part 322. By using the similar folding process as described in
In addition, a first side 3212 and a second side 3213 of the first winding unit 328 is coupled to the pin 323 and the extension parts 326, respectively. In some embodiments, an electronic component such as a transistor may be fixed on the extension part 326 such that the extension part 326 functions as a heat sink. By penetrating for example screws (not shown) through the holes 3261 and then coupled with corresponding nuts (not shown), the electronic component may be fixed on the extension part 326. The pins 3262 may be bonded on a system board (not shown).
b) is a schematic perspective view illustrating arrangement of the conductive winding module of
In the above embodiments, the conductive winding module of the present invention may be applied to a magnetic element such as a transformer. Since the conductive winding module is an unbroken multi-loop conductive piece, the overall volume of the conductive winding module is reduced. As the loop number of the conductive winding module is increased, the power density is increased.
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For facilitating securely assembling the transformer 4, the inner surfaces of the first magnetic part 431 and the second magnetic part 432 are bonded onto the conductive winding module 22 via adhesives 46. Similarly, the conductive winding modules 22 are bonded onto the circuit board 41 via adhesives 47.
From the above description, the conductive winding module of the present invention may be used as the secondary winding coil of the transformer. Since the conductive winding module is an unbroken multi-loop conductive piece, the overall volume of the conductive winding module is reduced and the power loss is decreased. Since the process of assembling the conductive winding module is very simple, the transformer is suitable for mass production. Moreover, the extension parts of the conductive winding module may facilitate dissipating heat of electronic components and increasing space utilization.
While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
Number | Date | Country | Kind |
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096130187 | Aug 2007 | TW | national |