CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to China Patent Application No. 202210931533.6 filed on Aug. 4, 2022 and China Patent Application No. 202310806227.4 filed on Jul. 3, 2023, the entire contents of which are incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
The present disclosure relates to a transformer, and more particularly to a transformer having reduced leakage inductance.
BACKGROUND OF THE INVENTION
In the field of industrial power, the power consumption of the motor is more than 65% of all industrial power. The motor having an inverter can reduce more than 40% of the power consumption and reduce the emission of carbon dioxide. In addition, the motor regulates its speed through the inverter so as to reduce the power consumption, reduce the impact of the starting current on the power grid, reduce the wear and tear of the motor and other mechanical equipment and decrease the maintenance cost. Consequently, the improved performance of the inverter can increase the overall performance of the motor.
The transformer disposed in the inverter usually has a multi-winding design due to different functions. Each winding in the multi-winding of the conventional transformer is disposed around the magnetic core in an irregular arrangement, which results in that the actual application voltage of the transformer is drifted easily. The manufacturing process of the conventional transformer is complex and cannot be automated. Consequently, the conventional transformer has the disadvantages of high labor cost, low performance of industrial automation, unstable product characteristics and dimensions, high leakage inductance and low voltage cross regulation.
Therefore, there is a need of providing a transformer to obviate the drawbacks encountered from the prior arts.
SUMMARY OF THE INVENTION
The present disclosure provides a transformer. One of the two first windings of the transformer of the present disclosure is disposed between the other one of the two first windings and the outer periphery surface of the bobbin main body. The second winding of the transformer is disposed between the two first windings. Namely, one of the two first windings, the second winding and the other one of the two first windings are stacked with each other in sequence. Compared with the conventional transformer, the leakage inductance of the transformer of the present disclosure is reduced substantially due to the arrangement of the two first windings and the second winding of the transformer as mentioned above. The arrangement of the two first windings and the second winding of the transformer is sequential and not easy to be interlaced and wound with each other. Consequently, the transformer of the present disclosure has the advantages of simple process and thus achieving automation easily, stable product quality and dimension, great product commonality and small volume. In addition, the second winding and the second circuit board are connected with each other in parallel. Consequently, the transformer of the present disclosure has the advantages of reduced leakage inductance and enhanced voltage cross regulation.
In accordance with an aspect of the present disclosure, there is provided a transformer. The transformer includes a magnetic core assembly, a bobbin, two first windings, a second winding and a second circuit board. The magnetic core assembly includes a first magnetic core and a second magnetic core. The bobbin includes a bobbin main body, a bobbin channel and a winding portion. The bobbin channel runs through two opposite sides of the bobbin main body. The winding portion is formed on an outer periphery surface of the bobbin main body. The two first windings are disposed around the winding portion. One of the two first windings is disposed between the other one of the two first windings and the outer periphery surface of the bobbin main body. The second winding is disposed around the winding portion and disposed between the two first windings. The second circuit board includes a second circuit board hole. The second circuit board hole and the bobbin channel are in communication with each other. The magnetic core assembly partially penetrates through the bobbin channel and the second circuit board hole. The second winding and the second circuit board are connected with each other in parallel.
The above contents of the present disclosure will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating a transformer according to a first embodiment of the present disclosure;
FIG. 2 is a schematic exploded view illustrating the transformer of FIG. 1;
FIG. 3 is a partial schematic cross-sectional view illustrating the transformer of FIG. 1 taken along the line A-A′;
FIG. 4 is a schematic equivalent circuit diagram illustrating the transformer of FIG. 1;
FIG. 5 is a schematic view illustrating a main circuit board of the transformer of FIG. 1; and
FIG. 6 is a schematic view illustrating a transformer according to a second embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present disclosure 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 disclosure 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.
FIG. 1 is a schematic view illustrating a transformer according to a first embodiment of the present disclosure. FIG. 2 is a schematic exploded view illustrating the transformer of FIG. 1. FIG. 3 is a partial schematic cross-sectional view illustrating the transformer of FIG. 1 taken along the line A-A′. FIG. 4 is a schematic equivalent circuit diagram illustrating the transformer of FIG. 1. As shown in FIGS. 1 to 3, the transformer 1 includes a magnetic core assembly 2, a bobbin 3, two first windings 41, a second winding 42, a first circuit board 5, a second circuit board 6 and a main circuit board 7.
The magnetic core assembly 2 includes a first magnetic core 21 and a second magnetic core 22. In this embodiment, as shown in FIG. 2, the first magnetic core 21 includes a first cover part 211, a first lateral part 212, a second lateral part 213 and a first middle part 214. The first lateral part 212 and the second lateral part 213 are respectively connected with two opposite sides of the first cover part 211 and located in two opposite sides of the transformer 1. The first middle part 214 is connected with the first cover part 211 and disposed between the first lateral part 212 and the second lateral part 213. The second magnetic core 22 includes a second cover part 221, a third lateral part 222, a fourth lateral part 223 and a second middle part 224. The second cover part 221 and the first cover part 211 are located in two opposite sides of the transformer 1. The third lateral part 222 and the fourth lateral part 223 are connected with two opposite sides of the second cover part 221 and located in two opposite sides of the transformer 1. The third lateral part 222 and the first lateral part 212 are spatially corresponding in position to each other and disposed between the second cover part 221 and the first cover part 211. The fourth lateral part 223 and the second lateral part 213 are spatially corresponding in position to each other and disposed between the second cover part 221 and the first cover part 211. The second middle part 224 is connected with the second cover part 221 and disposed between the third lateral part 222 and the fourth lateral part 223. The second middle part 224 and the first middle part 214 are spatially corresponding in position to each other and disposed between the second cover part 221 and the first cover part 211.
The bobbin 3 includes a bobbin main body 31, a bobbin channel 32 and at least one winding portion 33. For simplifying the figure, the structure of the magnetic core assembly 2 and the main circuit board 7 are not shown in FIG. 3. As shown in FIGS. 2 and 3, the bobbin main body 31 includes a first lateral wall 311, a second lateral wall 312 and an outer periphery surface 313. The first lateral wall 311 and the second lateral wall 312 of the bobbin main body 31 are located in two opposite sides of the bobbin main body 31. The first lateral wall 311 is located between the first cover part 211 of the first magnetic core 21 and the second lateral wall 312. The second lateral wall 312 is located between the second cover part 221 of the second magnetic core 22 and the first lateral wall 311. The outer periphery surface 313 of the bobbin main body 31 is located between the first lateral wall 311 and the second lateral wall 312. As shown in FIGS. 2 and 3, the first lateral wall 311 of the bobbin main body 31 is protruded out of the outer periphery surface 313, and the second lateral wall 312 of the bobbin main body 31 is protruded out of the outer periphery surface 313. In this embodiment, the number of the winding portion 33 of the bobbin 3 is one. The winding portion 33 is defined by the first lateral wall 311 protruded out of the outer periphery surface 313, the second lateral wall 312 protruded out of the outer periphery surface 313 and the outer periphery surface 313 collaboratively, so as to form the winding portion 33 on the outer periphery surface 313 of the bobbin main body 31. The bobbin main body 31 has a hollow structure to form the bobbin channel 32. The bobbin channel 32 runs through the first lateral wall 311 and the second lateral wall 312 of the bobbin main body 31.
In this embodiment, the bobbin 3 further includes a first receiving portion 314, a second receiving portion 315, two first protrusions 341 and two second protrusions 342. The first receiving portion 314 and the second receiving portion 315 are disposed on two opposite sides of the bobbin main body 31. The first receiving portion 314 is connected with one side of the first lateral wall 311 of the bobbin main body 31. The first receiving portion 314 and the bobbin channel 32 are staggered with each other, so that the first receiving portion 314 is not covered on the bobbin channel 32. When the transformer 1 has been assembled completely, the first middle part 214 of the first magnetic core 21 of the magnetic core assembly 2 penetrates through the first circuit board hole 52 and the bobbin channel 32, and the second middle part 224 of the second magnetic core 22 of the magnetic core assembly 2 penetrates through the second circuit board hole 62 and the bobbin channel 32, so that the first middle part 214 of the first magnetic core 21 and the second middle part 224 of the second magnetic core 22 are connected with each other within the bobbin channel 32. Meanwhile, as shown in FIG. 1, the first receiving portion 314 is adjacent to the first cover part 211 of the first magnetic core 21, the edge of the first receiving portion 314 and the first cover part 211 are located at the same plane, and the plane is parallel to the first lateral wall 311 of the bobbin main body 31. In this embodiment, as shown in FIG. 2, the first receiving portion 314 further includes a first concave 316. The first concave 316 is concavely formed on the top surface of the first receiving portion 314. The first concave 316 includes a first slot 317. The second receiving portion 315 is connected with one side of the second lateral wall 312 of the bobbin main body 31. The second receiving portion 315 and the bobbin channel 32 are staggered with each other, so that the second receiving portion 315 is not covered on the bobbin channel 32. When the transformer 1 has been assembled completely, the first middle part 214 of the first magnetic core 21 of the magnetic core assembly 2 penetrates through the first circuit board hole 52 and the bobbin channel 32, and the second middle part 224 of the second magnetic core 22 of the magnetic core assembly 2 penetrates through the second circuit board hole 62 and the bobbin channel 32, so that the first middle part 214 of the first magnetic core 21 and the second middle part 224 of the second magnetic core 22 are connected with each other within the bobbin channel 32. Meanwhile, as shown in FIG. 1, the second receiving portion 315 is adjacent to the second cover part 221 of the second magnetic core 22, and the edge of the second receiving portion 315 and the second cover part 221 are located at the same plane, and the plane is parallel to the second lateral wall 312 of the bobbin main body 31. In this embodiment, the second receiving portion 315 further includes a second concave 318. The second concave 318 is concavely formed on the top surface of the second receiving portion 315. The second concave 318 includes a second slot. The second slot is not shown in FIG. 2, but it is obvious that the second slot is spatially corresponding in position to the first slot 317. The two first protrusions 341 and the first concave 316 are disposed on two opposite surfaces of the first receiving portion 314. The two first protrusions 341 are disposed at two opposite sides of the first concave 316. The two second protrusions 342 and the second concave 318 are disposed on two opposite surfaces of the second receiving portion 315. The two second protrusions 342 are disposed at two opposite sides of the second concave 318.
As shown in FIGS. 3 and 4, the two first windings 41 form a first primary coil 81 of the transformer 1 collaboratively. The two first windings 41 are disposed around the winding portion 33. One of the two first windings 41 is disposed around the winding portion 33 and disposed between the other one of the two first windings 41 and the outer periphery surface 313 of the bobbin main body 31. Portion of the first winding 41 passes through the bobbin main body 31 of the bobbin 3 so as to connect to the two first protrusions 341 of the bobbin main body 31 of the bobbin 3. The second winding 42 forms a first secondary coil 82 of the transformer 1. The second winding 42 is disposed around one of the two first windings 41 and disposed around the winding portion 33. The second winding 42 is disposed between one of the two first windings 41 and the other one of the two first windings 41, that is, disposed between the two first windings 41. Namely, one of the two first windings 41, the second winding 42 and the other one of the two first windings 41 are stacked with each other in sequence. Portion of the second winding 42 passes through the bobbin main body 31 of the bobbin 3 so as to connect to the two second protrusions 342 of the bobbin main body 31 of the bobbin 3.
The wiring of the first circuit board 5 forms a second primary coil 83 of the transformer 1, as shown in FIG. 4. As shown in FIGS. 1 and 2, the first circuit board 5 is disposed between the first cover part 211 of the first magnetic core 21 and the first lateral wall 311 of the bobbin main body 31. The first circuit board 5 is further disposed between the first cover part 211 of the first magnetic core 21 and the second circuit board 6. The first circuit board 5 includes a first circuit board main body 51 and a first circuit board hole 52. The first circuit board hole 52 runs through the first circuit board main body 51. The first circuit board hole 52 and the bobbin channel 32 are spatially corresponding in position to each other. The wiring of the second circuit board 6 forms a second secondary coil 84 of the transformer 1, as shown in FIG. 4. As shown in FIGS. 1 and 2, the second circuit board 6 is disposed between the second cover part 221 of the second magnetic core 22 and the second lateral wall 312 of the bobbin main body 31. The second circuit board 6 is further disposed between the second cover part 221 of the second magnetic core 22 and the first circuit board 5. The second circuit board 6 includes a second circuit board main body 61 and a second circuit board hole 62. The second circuit board hole 62 runs through the second circuit board main body 61. The second circuit board hole 62 and the bobbin channel 32 are spatially corresponding in position to each other. The first circuit board hole 52, the second circuit board hole 62 and the bobbin channel 32 are in communication with each other. The first middle part 214 of the first magnetic core 21 of the magnetic core assembly 2 penetrates through the first circuit board hole 52 and the bobbin channel 32. The second middle part 224 of the second magnetic core 22 of the magnetic core assembly 2 penetrates through the second circuit board hole 62 and the bobbin channel 32. The first middle part 214 of the first magnetic core 21 and the second middle part 224 of the second magnetic core 22 are connected with each other within the bobbin channel 32, so that the two first windings 41 and the second winding 42 are disposed around the first middle part 214 of the first magnetic core 21 and the second middle part 224 of the second magnetic core 22. The first lateral part 212 of the first magnetic core 21 and the third lateral part 222 of the second magnetic core 22 are connected with each other. The second lateral part 213 of the first magnetic core 21 and the fourth lateral part 223 of the second magnetic core 22 are connected with each other.
The main circuit board 7 is disposed on one side of the magnetic core assembly 2 and adjacent to the first receiving portion 314 and the second receiving portion 315 of the bobbin 3, as shown in FIG. 1. The two first protrusions 341, the two second protrusions 342, the first circuit board 5 and the second circuit board 6 vertically inserts through and disposed on the main circuit board 7, respectively. The two second protrusions 342 and the second circuit board 6 are connected with each other in parallel through the wiring of the main circuit board 7.
From the above, one of the two first windings 41 of the transformer 1 is disposed between the other one of the two first windings 41 and the outer periphery surface 313 of the bobbin main body 31. The second winding 42 of the transformer 1 is disposed between the two first windings 41. Namely, one of the two first windings 41, the second winding 42 and the other one of the two first windings 41 are stacked with each other in sequence. While in the conventional transformer, each winding is disposed around the magnetic core in an irregular arrangement. Compared with the conventional transformer, the leakage inductance of the transformer 1 of the present disclosure is reduced substantially due to the arrangement of the two first windings 41 and the second winding 42 of the transformer 1 as mentioned above. The arrangement of the two first windings 41 and the second winding 42 of the transformer 1 of the present disclosure is sequential and not easy to be interlaced or wound with each other. Consequently, the transformer 1 has the advantages of simple process and thus achieving automation easily, stable product quality and dimension, great product commonality and small volume. In addition, the second winding 42 and the second circuit board 6 are connected with each other in parallel. Consequently, the transformer 1 of the present disclosure has the advantages of reduced leakage inductance and enhanced voltage cross regulation.
Please refer to FIG. 2. In this embodiment, the first circuit board main body 51 includes a first sub main body 511 and a second sub main body 512. The first sub main body 511 and the second sub main body 512 are integrally formed into one piece. The first circuit board hole 52 is located at the first sub main body 511. The first circuit board main body 51 is inserted into the first slot 317, so that at least portion of the first sub main body 511 is disposed in the first concave 316, and at least portion of the second sub main body 512 is disposed on the bottom surface of the first receiving portion 314. The first sub main body 511 of the first circuit board main body 51 is disposed between the first lateral wall 311 of the bobbin main body 31 and the first cover part 211 of the first magnetic core 21. The first circuit board hole 52 is in communication with the bobbin channel 32, so that the first middle part 214 of the first magnetic core 21 penetrates through the first circuit board hole 52 and the bobbin channel 32 in sequence. The second circuit board main body 61 includes a third sub main body 611 and a fourth sub main body 612. The third sub main body 611 and the fourth sub main body 612 are integrally formed into one piece. The second circuit board hole 62 is located at the third sub main body 611. The second circuit board main body 61 is inserted into the second slot, so that at least portion of the third sub main body 611 is disposed in the second concave 318, and at least portion of the fourth sub main body 612 is disposed on the bottom surface of the second receiving portion 315. The third sub main body 611 of the second circuit board main body 61 is disposed between the second lateral wall 312 of the bobbin main body 31 and the second cover part 221 of the second magnetic core 22. The second circuit board hole 62 is in communication with the bobbin channel 32, so that the second middle part 224 of the second magnetic core 22 penetrates through the second circuit board hole 62 and the bobbin channel 32 in sequence.
FIG. 5 is a schematic view illustrating a main circuit board of the transformer of FIG. 1. As shown in FIGS. 1, 2 and 5, the surface of the main circuit board 7 includes two circuit board slots 71, a plurality of protrusion slots 72 and a plurality of wirings 73. Each wiring 73 is connected between the corresponding circuit board slot 71 and the corresponding protrusion slot 72, so that the circuit board slot 71 is electrically connected with the corresponding protrusion slot 72. The first circuit board 5 and the second circuit board 6 are inserted into the corresponding circuit board slot 71 of the main circuit board 7, respectively. The two first protrusions 341 and the two second protrusions 342 are inserted into the corresponding protrusion slot 72 of the main circuit board 7, respectively. One end of the wiring of the second circuit board 6 and one of the two second protrusions 342 are connected with each other through the corresponding wiring 73 of the main circuit board 7. The other end of the wiring of the second circuit board 6 and the other one of the two second protrusions 342 are connected with each other through the other corresponding wiring 73 of the main circuit board 7. Namely, the second circuit board 6 and the two second protrusions 342 are connected with each other in parallel. The two leading ends of the second winding 42 are connected with the two second protrusions 342 of the bobbin 3, respectively, so that the second winding 42 and the second circuit board 6 are connected with each other in parallel.
FIG. 6 is a schematic view illustrating a transformer according to a second embodiment of the present disclosure. In the first embodiment, the wirings of the transformer 1 are connected through the main circuit board 7. Compared with the transformer 1 of the first embodiment of the present disclosure, the wirings of the transformer 1a of this embodiment are connected by jumping wire. As shown in FIG. 6, the two ends of the second winding of the transformer 1a of this embodiment are connected with the two second protrusions 342, respectively. The position of the second winding of the transformer 1a of this embodiment is similar to the second winding 42 of the transformer 1 of the first embodiment, as shown in FIG. 3. The transformer 1a of this embodiment includes a first jump wire 91 and a second jump wire 92. The first jump wire 91 is electrically connected between one end of the wiring of the second circuit board 6 and one of the two second protrusions 342. The second jump wire 92 is electrically connected between the other end of the wiring of the second circuit board 6 and the other one of the two second protrusions 342. Consequently, the second circuit board 6 and the second winding are connected with each other in parallel with two jump wires. In some other embodiments, the two leading ends of the second winding are not pass through the two second protrusions 342, respectively. Namely, the two leading ends of the second winding are electrically connected with two ends of the wiring of the second circuit board 6 via the jump wires directly so as to connect the second circuit board 6 and the second winding in parallel.
As mentioned above, one of the two first windings of the transformer of the present disclosure is disposed between the other one of the two first windings and the outer periphery surface of the bobbin main body. The second winding of the transformer is disposed between the two first windings. Namely, one of the two first windings, the second winding and the other one of the two first windings are stacked with each other in sequence. Compared with the conventional transformer, the leakage inductance of the transformer of the present disclosure is reduced substantially due to the arrangement of the two first windings and the second winding of the transformer as mentioned above. The arrangement of the two first windings and the second winding of the transformer is sequential and not easy to be interlaced or wound with each other. Consequently, the transformer of the present disclosure has the advantages of simple process and thus achieving automation easily, stable product quality and dimension, great product commonality and small volume. In addition, the second winding and the second circuit board are connected with each other in parallel. Consequently, the transformer of the present disclosure has the advantages of reduced leakage inductance and enhanced voltage cross regulation.
While the disclosure 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 disclosure 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.
Patent Application
20240047130
