CN217719195U

CN217719195U - Metal sheet and winding frame cladding injection structure and transformer

Info

Publication number: CN217719195U
Application number: CN202220717777.XU
Authority: CN
Inventors: 郑益吉; 黄健敉; 魏彭垚
Original assignee: Delta Electronics Dongguan Co Ltd
Current assignee: Delta Electronics Dongguan Co Ltd
Priority date: 2022-03-29
Filing date: 2022-03-29
Publication date: 2022-11-01
Anticipated expiration: 2032-03-29

Abstract

The utility model provides a sheetmetal and bobbin cladding injection structure and bobbin and sheetmetal piece coating forming's transformer, cladding injection structure includes bobbin and sheetmetal, the bobbin with the sheetmetal passes through mould cladding mode integrated into one piece of moulding plastics. The metal sheet and the winding frame in the coating injection structure are coated and molded by using the mold, and the metal sheet is inserted into the cavity of the plastic mold for mold closing and injection molding, so that manual assembly or development and assembly equipment are reduced.

Description

Metal sheet and winding frame cladding injection structure and transformer

Technical Field

The utility model relates to a magnetic element technical field especially relates to a sheetmetal and bobbin cladding injection structure and bobbin and sheetmetal coating shaping's transformer.

Background

The switching power supply tends to have high efficiency and high power density, and how to reduce labor cost to realize automatic production is a problem which must be considered in the field of magnetic element design.

The metal sheet type transformer has the advantages of high efficiency, high power density, good heat dissipation and the like, but the automatic assembly of the winding frame and the metal sheets is not easy to realize in the current design, more manpower and the number of dies are required for assembly, the cost is higher, how to design the metal sheet type transformer which can meet the requirements of high efficiency and high power density and can be automatically produced is the technical problem to be solved urgently at present.

SUMMERY OF THE UTILITY MODEL

The utility model aims at providing a sheetmetal and bobbin cladding injection structure and transformer, reached and to have satisfied high efficiency, high power density requirement, again can automated production's purpose.

In order to achieve the above object, the utility model provides a sheetmetal and bobbin cladding injection structure, cladding injection structure includes bobbin and sheetmetal, the bobbin with the sheetmetal passes through mould cladding mode integrated into one piece of moulding plastics.

In some of these embodiments, the sheet metal cladding ring is disposed on an outer peripheral side of the bobbin.

In some of these embodiments, the metal sheet has two end portions, and the metal sheet extends from one end portion to the other end portion to form a ring-shaped structure with an opening; the bobbin comprises an outer wall and a through hole surrounded by the outer wall, and the metal sheet and the outer wall of the bobbin are of an integral structure.

In some embodiments, the over-molded structure includes a bobbin and a plurality of metal sheets, and the metal sheets are sequentially arranged at intervals.

The utility model also provides a transformer formed by coating the bobbin with the metal sheet, which comprises the metal sheet and bobbin coating injection molding structure, a primary winding wound on the bobbin of the coating injection molding structure, and a magnetic core;

wherein the metal sheet in the over-molding structure is used as a secondary winding of the transformer, and the magnetic core passes through the through hole of the bobbin.

In some embodiments, the primary winding includes a plurality of sub-primary windings, the number of the metal sheets is multiple, the sub-primary windings and the metal sheets are sequentially and alternately arranged, and the plurality of sub-primary windings are connected in series.

In some embodiments, the number of the metal sheets is multiple, and the extending directions of the two end parts of the multiple metal sheets are consistent.

In some embodiments, the number of the metal sheets is multiple, two end portions of a part of the metal sheets extend along a first direction, and two end portions of the other part of the metal sheets extend along a second direction, and the first direction is opposite to the second direction.

In some of these embodiments, the over-molded structure includes an auxiliary winding slot for winding an auxiliary winding.

In some of the embodiments, the magnetic core includes a side pillar, a center pillar, a first connection part connecting one ends of the side pillar and the center pillar, and a second connection part connecting the other ends of the side pillar and the center pillar; the center post passes through the through hole of the bobbin, and the side post is located outside the bobbin.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to these drawings without inventive labor.

Fig. 1 is an exploded view of a transformer formed by coating a bobbin with a metal sheet according to a first embodiment of the present invention;

fig. 2 is another exploded view of the transformer formed by coating the bobbin with the metal sheet according to the first embodiment of the present invention;

FIG. 3 is a schematic structural view of an over-molding structure of the metal sheet and the bobbin shown in FIGS. 1 and 2;

fig. 4 is an exploded view of a transformer formed by coating a bobbin with a metal sheet according to a second embodiment of the present invention;

FIG. 5 is a schematic structural view of the over-molding structure of the metal sheet and the bobbin shown in FIG. 4;

fig. 6 is an exploded view of a transformer formed by coating a bobbin with a metal sheet according to a third embodiment of the present invention;

FIG. 7 is a schematic structural view of the metal sheet and bobbin injection molding structure shown in FIG. 6

Wherein:

1-coating injection structure;

11-a bobbin;

111-an outer wall;

112-through holes;

12-a metal sheet;

121-a first end portion;

122-a second end;

123-opening;

13-auxiliary winding slots;

131-an auxiliary winding;

2-primary winding;

21-a sub-primary winding;

3-a magnetic core;

31-side columns;

32-a center pillar;

33-a first connection;

34-a second connection;

x-a first direction;

y-second direction.

Detailed Description

The following detailed description of the embodiments of the present invention will be provided in conjunction with the accompanying drawings and specific embodiments for further understanding the objects, aspects and functions of the present invention, but not for limiting the scope of the appended claims.

Where certain terms are used in the specification and following claims to refer to particular components or features, those skilled in the art will understand that various terms or numbers may be used by a skilled user or manufacturer to refer to the same component or feature. This specification and the claims that follow do not intend to distinguish between components or features that differ in name but not function. In the following description and in the claims, the terms "include" and "comprise" are used in an open-ended fashion, and thus should be interpreted to mean "include, but not limited to. In addition, the term "coupled" is intended to include any direct or indirect coupling. Indirect means of connection include connection by other means.

It should be noted that in the description of the present invention, the terms "lateral", "longitudinal", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and "about", or "approximately", "substantially", "left and right", etc., indicate the orientation or positional relationship or parameters, etc., based on the orientation or positional relationship shown in the drawings, which are only for convenience of description and simplification of the description, and do not indicate or imply that the device or element referred to must have a specific orientation, a specific size or be constructed and operated in a specific orientation, and therefore, should not be construed as limiting the present invention.

Two sheet metal transformer configurations are known to the applicant, the first being a transformer configuration in which the sheet metal is assembled to a bobbin design; the second type is a transformer structure designed by assembling a bobbin first and then assembling a metal sheet. The combined metal sheet or the combined winding frame in the structure needs manual assembly or development of automatic equipment; the metal sheet and the winding frame have combined tolerance, the too large tolerance can cause the phenomenon of too loose after assembly, so that the winding frame can not effectively fix the metal sheet, and the too small tolerance can cause the too tight assembly, so that the metal sheet can not be effectively assembled; the fixing method of the structure is that the metal card point and the clamping groove of the winding frame are fixed by a tenon structure, and the metal card point and the clamping groove of the winding frame are influenced by stress during winding, so that the pin distance offset is caused by the spreading phenomenon of the metal sheet pin, and a pin aligning jig is additionally used for performing a pin aligning process; the bobbin assembly is easy to damage and has high reject ratio; in addition, the metal sheet multi-group output needs two or more winding frame dies, and the development cost is increased.

To the above problem, the utility model discloses a sheetmetal and bobbin cladding injection structure and contain this cladding injection structure's transformer is disclosed to the first embodiment. Specifically, fig. 1 and fig. 2 are the exploded view of the transformer formed by coating the bobbin with the metal sheet shown in the first embodiment of the present invention, the primary winding 2 in fig. 1 is not installed on the bobbin 11, the primary winding 2 in fig. 2 is installed on the bobbin 11, fig. 3 is the schematic structural diagram of the injection molding structure of the metal sheet and the bobbin coating shown in fig. 1 and fig. 2, refer to fig. 1-3, this embodiment discloses a transformer formed by coating the bobbin with the metal sheet, which includes a metal sheet and the bobbin coating injection molding structure 1, the primary winding 2 wound on the bobbin 11 of the coating injection molding structure 1, and the magnetic core 3.

Further, as shown in fig. 3, the sheet metal and bobbin injection molding structure 1 in the present embodiment includes a bobbin 11 and a sheet metal 12, the bobbin 11 and the sheet metal 12 are integrally formed by a mold injection molding method, and the sheet metal 12 is disposed around an outer periphery of the bobbin 11; in this embodiment the cladding injection structure 1 includes a bobbin 11 and a plurality of sheetmetal 12, a plurality of sheetmetals 12 are arranged at interval in proper order, and the cladding shaping design only needs one set of bobbin mould in this embodiment, reducible mould development cost.

In the embodiment, the metal sheet 12 and the winding frame 11 are coated and injection molded by using a mold, and the metal sheet 12 is inserted into a cavity of a plastic mold to be subjected to mold closing and injection molding, so that manual assembly or development of assembly equipment is reduced; by adopting the coating injection structure, the metal sheet 12 and the winding frame 11 have no assembly accumulated tolerance, so that the width of a winding groove is more fixed, and the characteristic of the transformer is more stable; the metal sheet is better in coating forming fixation, the pin outlet precision of the metal sheet is high after winding, the pin alignment process is reduced, and the pin length tolerance of the metal sheet 12 is reduced.

Specifically, in the present embodiment, the metal sheet 12 has two end portions, specifically, a first end portion 121 and a second end portion 122, and the metal sheet 12 extends from one end portion to the other end portion to form a ring structure with an opening 123, it should be noted that the metal sheet may extend from the first end portion 121 to the second end portion 122 to form a ring structure with an opening 123, or the metal sheet may extend from the second end portion 122 to the first end portion 121 to form a ring structure with an opening 123.

Specifically, in the present embodiment, the bobbin 11 includes an outer wall 111 and a through hole 112 surrounded by the outer wall 111, the metal sheet 12 is integrated with the outer wall 111 of the bobbin 11, the metal sheet 12 in the over-molded structure 1 is used as a secondary winding of the transformer, and the magnetic core 3 passes through the through hole 112 of the bobbin 11.

Referring to fig. 2, the magnetic core 3 of the present embodiment includes a side pillar 31, a center pillar 32, a first connecting portion 33 and a second connecting portion 34, wherein the first connecting portion 33 connects one end of the side pillar 31 and one end of the center pillar 32, and the second connecting portion 34 connects the other end of the side pillar 31 and the other end of the center pillar 32; the center pillar 32 passes through the through hole 112 of the bobbin 11, and the side pillar 31 is positioned outside the bobbin 11. It should be noted that the magnetic core 3 in this embodiment is formed by splicing two E-shaped magnetic cores, the center pillar 32 is formed by splicing two parts, and each of the two side pillars 31 is also formed by splicing two parts. However, in other embodiments, the structure of the magnetic core 3 may be in other forms, for example, two UU-shaped magnetic cores are spliced together, or one E-shaped magnetic core and one I-shaped magnetic core are spliced together, and the structural form of the magnetic core is not particularly limited in this application.

Referring to fig. 1-2, in the present embodiment, the primary winding 2 includes a plurality of sub-primary windings 21, the number of the metal sheets 12 is a plurality, for example, 4, the sub-primary windings 21 and the metal sheets 12 are sequentially and alternately arranged, and the plurality of sub-primary windings 21 are connected in series. Referring to fig. 3, in the embodiment, the number of the metal sheets 12 is plural, the extending directions of the two end portions of the metal sheets 12 are the same, for example, the foot outlet directions of the 4 metal sheets 12 are downward, and it is worth noting that the extending directions of the two end portions of the metal sheets in the embodiment of the present invention are not limited to be the same, and may also be arranged in different directions. The number of metal sheets 12 and their foot-projecting direction are not particularly limited in this application.

Fig. 4 is an exploded view of a transformer structure formed by coating a bobbin with a metal sheet according to a second embodiment of the present invention, in which the pin-out directions of the metal sheet 12 are not the same, and fig. 5 is a schematic structural view of the metal sheet and bobbin-coated injection structure shown in fig. 4; referring to fig. 4-5, the second embodiment of the present invention provides a transformer structure formed by coating a bobbin with a metal sheet, the transformer structure is similar to the transformer structure disclosed in the first embodiment, and is not repeated herein, and the main difference is that the number of the metal sheet 12 in the coating injection structure 1 in this embodiment is multiple, for example, 6, part of the two end portions of the metal sheet 12 extend along the first direction X, the other part of the two end portions of the metal sheet 12 extend along the second direction Y, the first direction X is opposite to the second direction Y, for example, the pin outlet direction of 3 metal sheets 12 is upward, and the pin outlet direction of the other 3 metal sheets 12 is downward. The arrangement of the metal sheet 12 with different pin-out directions can make the layout of power supply parts more compact, improve the power density of the power supply, increase the copper thickness of a path of a single-path PCB and be applied to a high-efficiency power supply.

Fig. 6 is an exploded view of a transformer structure formed by coating a bobbin with a metal sheet according to a third embodiment of the present invention, and fig. 7 is a schematic structural view of an injection molding structure of the metal sheet and the bobbin shown in fig. 6; referring to fig. 6-7, the utility model discloses the third embodiment provides a bobbin and sheet metal piece coating forming's transformer, and this transformer structure is similar with the transformer structure that the first embodiment is disclosed, no longer gives unnecessary details here, and the main difference lies in, and this embodiment is on the basis of the first embodiment, cladding injection structure 1 has further included auxiliary winding wire winding groove 13, auxiliary winding wire winding groove 13 is used for around establishing auxiliary winding 131, so can the integrated auxiliary line, has increased the variety of circuit application scheme, has reduced power cost.

In the metal sheet and winding frame cladding injection structure and the transformer formed by cladding the winding frame and the metal sheet, the metal sheet and the winding frame are formed by cladding through a mold, and the metal sheet is inserted into a cavity of a plastic mold for mold closing and injection molding, so that manual assembly or development of assembly equipment is reduced; the metal sheet and the winding frame have no assembly accumulated tolerance, so that the width of the winding slot is more fixed, and the transformer characteristic is more stable; the structure formed by the metal sheet and the winding frame in an cladding mode has better fixation, the pin outlet precision of the metal sheet is high after winding, the pin aligning process is reduced, and the tolerance of the metal sheet pin length is reduced; the utility model provides a bobbin and sheet metal cladding shaping design only need one set of bobbin mould, reducible mould development cost.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in other forms, and any person skilled in the art may use the above-mentioned technical contents to change or modify the equivalent embodiment into equivalent changes and apply to other fields, but any simple modification, equivalent change and modification made to the above embodiments according to the technical matters of the present invention will still fall within the protection scope of the technical solution of the present invention.

Claims

1. The utility model provides a sheetmetal and bobbin cladding injection structure which characterized in that: the cladding injection molding structure comprises a winding frame and a metal sheet, and the winding frame and the metal sheet are integrally molded in a mold cladding injection molding mode;

the cladding injection molding structure comprises a bobbin and a plurality of metal sheets, wherein the metal sheets are sequentially arranged at intervals.

2. The sheet metal and bobbin overmold structure of claim 1, wherein: the metal sheet covering ring is arranged on the outer periphery side of the winding frame.

3. The sheet metal and bobbin overmold structure of claim 1 or 2, wherein: the metal sheet is provided with two end parts, and the metal sheet extends from one end part to the other end part to form an annular structure with an opening; the bobbin comprises an outer wall and a through hole surrounded by the outer wall, and the metal sheet and the outer wall of the bobbin are of an integral structure.

4. A transformer with a winding frame and a metal sheet formed in a coating mode is characterized in that: an overmolded structure comprising a metal sheet according to any one of claims 1 to 3 and a bobbin, a primary winding wound on the bobbin of the overmolded structure, and a magnetic core;

wherein the metal sheet in the over-molded structure is used as a secondary winding of the transformer, and the magnetic core passes through the through hole of the bobbin.

5. The transformer of claim 4, wherein: the primary winding comprises a plurality of sub primary windings, the sub primary windings and the metal sheets are sequentially and alternately arranged, and the plurality of sub primary windings are connected in series.

6. The transformer of claim 4, wherein: the extending directions of both end portions of the plurality of metal pieces are identical.

7. The transformer of claim 4, wherein: the two end parts of part of the metal sheet extend along a first direction, and the two end parts of the rest part of the metal sheet extend along a second direction, wherein the first direction is opposite to the second direction.

8. The transformer of claim 4, wherein: the cladding injection molding structure comprises an auxiliary winding slot, and the auxiliary winding slot is used for winding an auxiliary winding.

9. The transformer of claim 4, wherein: the magnetic core comprises a side column, a middle column, a first connecting part and a second connecting part, wherein the first connecting part is connected with one end of the side column and one end of the middle column, and the second connecting part is connected with the other end of the side column and the other end of the middle column;

the center post passes through the through hole of the bobbin, and the side post is located outside the bobbin.