Background technology
Transformer is used to multiple field, for example, the power subsystem that is used for Halogen lamp LED, wherein input line voltage (for example, the supply voltage that is generally the 220-240 volt that most of European countries use, and the representative value that most of American States use is the 100-120 volt) is converted into the output voltage of 6 volts, 12 volts or 24 volts.Transformer also usually is used as the output isolation transformer in the electronic converter of Halogen lamp LED, to produce 12 volts output voltage.
So-called " ring-like " transformer usually is used to above-mentioned application.In the transformer of these prior aries, for the operating voltage up to 250 volts, the wall of roll must have about 1 millimeter thickness, so as to satisfy as among EN61347 (general and safety requirements) defined require SELV (safety is added low pressure).
At present, also use thick copper cash at secondary winding.These leads show enough rigidity, thereby allow to place automatically during assembling transformer.The end of elementary winding is soldered to the pin that is associated on the contrary.Electronic transformer for Halogen lamp LED is especially like this.These electronic transformers are actually step-down transformer, just following transformer, and wherein the voltage of secondary winding is lower than the voltage of elementary winding, thereby causes the electric current of secondary winding higher with respect to the electric current of elementary winding.This causes the lead that must be soldered to pin of primary side thinner, so that have enough rigidities.Usually the quite simple roll of choice structure mainly is in order to allow the fixedly magnetic part of pin and secondary wire and support transformer.In some cases, this comprises inevitably and need use triple insulated wire at secondary winding, and the insulation belt also additionally is set.In order to satisfy such as requirement about the standard of the EN61347 of SELV, because secondary winding externally, if so relate to that all parts of primary side do not insulate then these parts must be placed in apart from 3 millimeters places of secondary winding, if these parts basic insulations, then these parts are very near secondary winding.Under remaining situation, have basic insulation if relate to all parts of primary side, then these parts must be placed in apart from this winding 3 mm distance places at least, and if this insulation is not set, then this distance is at least 6 millimeters.
In addition, from the viewpoint of Electromagnetic Compatibility, these transformers are critical (critical) and the heat protection that requires complexity, and all these is the cost-efficient factor that hinders final solution.
The other key factor that needs to consider relates to:
-transformer is installed in the very little substrate (such as narrow printed circuit board (PCB) or PCB),
If-other parts (such as the parts of the primary side that relates to transformer) of being disposed on the same plate have basic insulation, then transformer is placed near these parts ground very much, if perhaps these parts do not have basic insulation, then these parts are placed on less than 1 mm distance place, and make the conductive copper track that is connected to secondary winding be laid in the so-called component side of this plate, just be laid in parts and be installed to that side of the plate on it
-reduce the height of final products, and
-allow full-automatic assembling transformer.
For example, the typical case that will satisfy in the present application requires: transformer apart from the maximum height of substrate less than 14.5 millimeters, power handling capability (European supply voltage) under the nominal operation condition is 75 watts, and the fixing end of winding conducting wire, so that the problem that may occur during the assembling stage of the transformer when avoiding making.
Summary of the invention
Though disclosed transformer has solved these problems and demand well in EP-B-0 793 243, still need to grope further improved structure, form the preamble of claim 1 according to document EP-B-0793 243.
Therefore, the purpose of this invention is to provide a kind of transformer, this transformer is suitable for satisfying above-mentioned requirements with being entirely satisfactory.
According to the present invention, this purpose realizes that by a kind of transformer this transformer has the feature of being set forth in claim subsequently.The invention still further relates to a kind of corresponding assembly method.The integral part of this disclosure of invention that provides is provided these claims.
Particularly preferred embodiment of the present invention adopts EFD type (or EFF type) magnetic core to replace FERRITE CORE.EFD type magnetic core is a kind of E type magnetic core, but it is than E type magnetic core " more flat ", and effective area equates.Like that, under nominal European halotronic condition of work, can carry the power of 75 wattage magnitudes, wherein apart from the maximum height of substrate less than 14.5 millimeters.
Particularly preferred embodiment of the present invention provides the existence around the roll of this magnetic core, and this roll allows whole transformer part compatible mutually with SELV (the additional low pressure of safety) insulating requirements.
The parts that relate to primary side can be placed near transformer ground very much, and secondary track can be laid in the component side of this plate, because secondary winding and magnetic core reinforced insulation (following EN61347), this is the outside current-carrying part of parts.
Preferably, transformer of the present invention comprises two winding chambers, and these two winding chambers are isolated from each other and closely place mutually.Also preferably, this structure is a dissymmetrical structure, and just (normally secondary winding chamber) is provided with insulation a chamber, and the form of insulation is a reinforced insulation, and the inverted configuration of this and EP-B-0793 243 adopts double insulation in the structure of EP-B-0793 243.Also (for example, by the extension of the cover cap that is associated with roll) is provided with insulation preferably in the magnetic core outside, and is not only in inside insulation to be set.
Transformer described here can be mounted (just, being positioned in the substrate such as PCB) automatically, even secondary wire is quite pliable and tough twisted wire.The end terminal of secondary winding preferably welds together with pin, therefore produces thick pin, and these thick pins are stable and can be fixed to vertical pins.By for example hole of groove (blind hole) form preferably is set, be convenient to winding conducting wire is welded to the operation of pin in transformer case.These grooves are retained in lead safely and may construct the appropriate location that (beakformation) cooperates with the beak that is set in this shell itself.
Preferably, roll shows additional stickup pin, is used for roll is fixed to printed circuit board (PCB).When the electrical connection pin of the welding ends with secondary winding became too thick, these additional pins were for being essential with the roll additional fastening to printed circuit board (PCB).
Embodiment
In the accompanying drawings, Reference numeral 1 whole expression is suitable for using the transformer of (for example being connected with Halogen lamp LED).This transformer intention is usually worked in being higher than the frequency range of basic frequency and is comprised following primary element:
-roll, this roll be usually by forming such as poly moulded insulation, and comprise elementary winding body and the secondary winding body that limits corresponding elementary winding chamber 21 and secondary winding chamber 22,
-elementary the winding 31 and the secondary winding 32 that are twined of the elementary winding body in elementary winding chamber 21 and secondary winding chamber 22 and secondary winding body respectively; And
-be disposed in the ferromagnetic core of the top of roll 2 by this way, so that cooperate, thereby when working, transformer produces the mutual impedance structure with elementary winding 31 and secondary winding 32.
Therefore two winding chambers 21 and 22 are isolated and are closely placed mutually, just placed side by side.
In Fig. 1 to 3, schematically show winding 31,32 and magnetic core 4 with broken/dotted line, just to the feature of being convenient to more clearly represent and understand roll 2.In Fig. 4, roll 2 only is shown.
Transformer 1 described here is particularly suitable for utilizing EFD type magnetic core (sometimes, some manufacturer of the Far East Area also is referred to as EFF type magnetic core) work.
The particularly preferred embodiment of structure described here is arranged to magnetic core 4 FERRITE CORE of EFD25 type.This core type slightly is different from standard E type magnetic core, because this magnetic core has the section (profile) of reduction when keeping identical effective area (Ae).It is favourable taking this magnetic core, because this magnetic core causes the integral thickness (highly) of transformer 1 lower, keeps good Power Processing capacity simultaneously.
Structure described here adopts this core type, guarantees fully compatible simultaneously as by the insulating requirements such as the prescribed by standard of EN 61347, EN 61347 relates to so-called SELV (the additional low pressure of safety) insulating requirements.
In fact, structure described here is by providing the reinforced insulation of secondary winding 32 that this insulation level is provided with respect to elementary winding 31 and FERRITE CORE 4.Like that, all electronic units that relate to elementary winding 31 all can be mounted very near FERRITE CORE 4 (can understand this fact best in Fig. 2).As used herein such, " very close " is meant that distance is lower than 1 millimeter, perhaps or even only is enough to avoid the distance of these parts directly contact mutually (just mutual " touch ").
By direct contrast, will understand, structure described here is different from disclosed structure among the EP-B-0 793 243, usually because such prior art constructions comprises the double insulation between elementary winding and the secondary winding.This adds that by the basic insulation between FERRITE CORE and the elementary winding supplementary insulation between FERRITE CORE and the secondary winding is provided with.
In the described structure, utilize between elementary winding 31 and the secondary winding 32 and at least 1 millimeter insulation thickness between secondary winding 32 and the FERRITE CORE here, realize the insulation level of strengthening (SELV).In addition, on the one hand between elementary winding 31 and secondary winding 32, and air " creepage (creepage) " is set on the other hand and between secondary winding 32 and FERRITE CORE 4 to fixed gap.
The value in such gap is at least 6 millimeters, and considers 6.4 millimeters added value when observing Unite States Standard UL 1310 (safety standards of grade 2 power subsystems).This standard is claimed by U.S.'s theme (AmericanSubject) UL 897A, is used for field erected LED (light-emitting diode) tool box so that cover, and wherein adopts transformer 1.
Especially, the protective cover of setting and adaptive electrical insulating material 52 is to be associated with the secondary winding chamber.This lid 52 is made up of the identical electrical insulating material of other parts that comprise roll usually.Therefore this lid 52 all is considered to the part of the roll 2 of transformer in all respects.
Therefore the thickness that surrounds all walls of secondary chamber be chosen as to have and be not less than 1 millimeter minimum thickness, in secondary chamber, twine secondary winding 32, and the preferred thickness of the sidewall of this chamber is 1.5 millimeters, because exist as below with the labyrinth (labyrinths) that further specifies.Among the implementation illustrated here embodiment, cover cap 52 integral body have approximate " omega " or " table top " shape (this can be understood best) in the front view of Fig. 3, and therefore the sidewall of secondary winding chamber is limited by the sidewall 520 of lid 52.
Its wall is generally 0.5 millimeter by the thickness of 320 walls expression, between the primary and secondary winding 31,32 in Fig. 2.
In order to ensure 6-6.4 millimeter creepage of expectation, all the perforation wall portion of those parts by setting up the end that is arranged in the secondary winding chamber in the roll structure and being set at cover 52 complementary wall and constructs at the two ends of secondary winding 32, sets up the labyrinth.
Especially, connect wall by making wall 320 between elementary winding 31 and the secondary winding 32 be equipped with groove 321 to set up first group, this groove 321 be suitable for connecting be set at the outstanding wall 521 that covers interior (just nearest) side of 52.The existence of in the plane graph of Fig. 4, understanding wall 521 best with and with the perforation relation that is set at the groove 321 in the wall 320.
By end wall 322 is set, this end wall 322 have be suitable for connecting with the central recess or the groove 323 of another wall 522 cooperations, this another wall 522 is outstanding from covering 52 inner surface, secondary winding 32 relative, outside (just, the distally) end sets up labyrinth arrangement like the universal class, as understanding best among Fig. 3.
The labyrinth arrangement that is associated with center wall 320 has about 6.7 millimeters typical nominal length, and this length is enough to provide between primary and secondary winding 31,32 and has surpassed effective creepage distance of 6.4 millimeters.The labyrinth arrangement that is associated with wall 322 is arranged to the nominal creepage distance that provides about 6.5 millimeters usually.
By control and secondary winding magnetic core 4 that is associated and the distance that is connected between the pin 6, provide another factor of guaranteeing the insulation level expected.These pins are outstanding from the lower surface of roll 2 usually.By taking any known for this purpose standard technique that these pins can be set, for example, these pins are set with the form of the metal pins in the plastics mould that is inserted into roll.Replacedly, pin 6 can be provided with the form of the global facility of roll plastics mould, twines above this roll plastics mould and the wire termination of welding secondary winding.This structure is illustrated in EP 04425772.3, and EP 04425772.3 is that the application's same Applicant was submitted to October 13 in 2004.
Be connected pin and can take similar structure at what be associated with elementary winding 21.Among the implementation illustrated here embodiment, be 4 by the quantity of the primary pins of 7 whole expressions, and the quantity of secondary pin 6 is 2.This can stipulate simply by the following fact: in fact elementary winding 22 can be arranged to comprise different tap/contact points, so that make that transformer 1 is suitable for providing identical output voltage simultaneously with different input voltage work.There is no need in that event, then can select the placement of primary pins easily.
Get back to the distance between secondary pin 6 and the magnetic core 4 once more, shown in representative value in the structure be at least 7.2 millimeters, this appears to satisfy the application who is conceived fully and guarantee the SELV insulation.
Another factor that plays effect in the level insulation of determining transformer described here is provided by the path between secondary pin 6 within the transformer (and secondary winding 32) and the FERRITE CORE 4.
This comprises the labyrinth formation of being determined by two that extend in the both sides of lid 52 horizontal L shaped extensions 524 in fact once more.When lid was inserted into its position, these extensions were covered by groove 324.Path by this labyrinth is far longer than 6.4 millimeters, this labyrinth be based upon between secondary winding and the FERRITE CORE or secondary track and FERRITE CORE on the component side of possible plate between.
From the view of Fig. 2, what will be further understood that is, the vertical height of cover cap 52 has with center wall 320 corresponding to maximums and to lid 52 distal end portion and reduces gradually, to reach and end wall 322 corresponding to minimum values, therefore avoids stretching out influence with respect to secondary pin 6 any.
Consider to expect to exist secondary connection track on the component side of PCB that so that guarantee the complete SELV compatibility of transformer described here at any possible application, transformer 1 is installed on this component side of PCB.
Lid 52 is designed to have integral body " omega " or " table top " shape by this way.As understanding best in the view of Fig. 1 and 2, not merely consistently extend with lid length 52 extension (" beak ") 523, but, with envelope or surround the magnetic core 4 of its whole extension, therefore support this magnetic core at its " secondary " end also along the longitudinal extension of transformer.
Like that, substantially exceed air path between secondary track 6.4 millimeters, possible and the FERRITE CORE can be for example by selectively changing transverse projections 523 vertical component height and easily obtain.May easily make beak 523 become two walls, these two walls are around the whole outer legs of FERRITE CORE, relate to the parts that are placed near the primary side the transformer so that this ferrite is shielded from.Like this, extension 523 will have the roughly shape of C shape, the outer legs that these extensions 523 surround magnetic core 4.
Be connected to corresponding pin set 6,7 about the end with winding 31,32, this specification is implicit has supposed that this situation of being discussed is a step-down applications.In step-down applications, the lead of elementary winding 31 is thin relatively and therefore pliable and tough, is suitable for keeping given shape simultaneously.For this lead, normal structure is for example taked by lead is twined and is welded to pin 7 in described structure optimization ground.
Boosting application (just, therefore wherein the voltage of secondary winding is higher than the voltage of elementary winding, causes electric current those application lower with respect to the electric current of elementary winding of secondary winding) in, when secondary winding 32 is used as elementary winding, foregoing is generally used for identical transformer, and vice versa for winding 31.
In typical step-down applications, the lead of secondary winding 32 (and lead of the elementary winding under this applicable cases that will be used to boost) can be three types: by insulation copper cash, twisted wire that enamel paint covered or the conductor of being made up of the braid of very thin lead.
Very firm by the copper cash itself that enamel paint covered, be different from independent pin, respective end can run through the essential part of roll 2 thus, and the effect of playing pin 6 itself, therefore allows automatic assembling transformer 1.
On the contrary, twisted wire or even (even worse) very the braid essence of thin wire is not hard, this braid must require it is wrapped on the pin, perhaps under any circumstance is fixed on the pin, so that produce the rigid member (pin) that is suitable for running through the installing hole in the printed circuit board (PCB).Yet this can cause following situation, and promptly high-current flow is crossed very thin pin, the temperature of the parts in that zone that therefore raises.Twisted wire is directly connected to the track/band that is set in the plate can reduces temperature 5-10 degree centigrade of secondary winding.At present, this can cause being had by operator's hand assembled most of transformers of twisted wire secondary winding.
In the described structure, two holes 8 of groove (blind hole just) form are set here near the roll secondary pin 6.
Preferably, direct manufacturing hole 8 during the molding process of roll 2.
The end of secondary winding 32 (schematically show, and hypothesis forms) by the braid of twisted wire or thin wire by W thus by groove 8 to be soldered to pin 6.Hole/groove 8 allows end W to remain on the fixed position safely, and wire termination W is soldered to pin 6 simultaneously, thereby produces very solid structure.
In the one side of back, should be understood that in a single day slicken solder enters by the employed common welding temperature of the coil winding machine that winding overhang is connected to pin, this slicken solder is exactly high polar liquid.It tends to fill the slit between the lead (as comprise twisted wire for example or lead braid those leads) inherently.Therefore when removing wire termination from welding groove, in fact these wire terminations will be compact and form one with metal pins 6.
Be suitable for the easy transformer 1 that assembles of automated manner by taking this structure, can making.This also has benefited from according to utilizing the PCB band and the nigh parts that are positioned to reduce the mentioned advantage of temperature at tie point place.
Therefore, under the situation of not damaging basic principle of the present invention, can be with respect to the content changing details and the embodiment that only illustrate and illustrate, and can not depart from of the present invention as by appended claim institute restricted portion.