KR20190090467A - Planar transformer and method for assembling thereof - Google Patents

Abstract

Disclosed is a planar transformer comprising: a core which can be separated into two parts of the upper side and the lower side; a coil assembly having an input terminal supplying an electric signal and including at least one primary coil stacked around the core; at least one secondary coil having an output terminal outputting the converted electric signal and stacked around the core; and a base having a post surrounding the core. The coils are stacked around the post. As coils without bobbins are stacked, the planar transformer allows coil components to be conveniently assembled and is suitable for mass production.

Description

Plate-type transformer and assembly method thereof {PLANAR TRANSFORMER AND METHOD FOR ASSEMBLING THEREOF}

The present invention relates to a flat transformer and a method for assembling thereof, and more particularly, to a flat transformer and a method for assembling the same, including a coil without bobbin, which can be used for transformer applications and coil components.

A coil is a wire wound like a copper wire in a spiral shape. Henry (H) is used as a unit to indicate the degree of properties of the coil. Winding the wire strengthens the properties of the coil and increases the value of Henry. The coil has a larger Henry value than the hollow core coil wound around the core of core or silicon. The distribution of Henry's values of coils typically used in electrical circuits ranges from micro Henry to Henry.

Electronic components that exhibit coil properties are called inductors, and their properties are called inductances. This is a concept corresponding to the capacitance that represents the capacitor and its properties.

When an alternating current flows through the coil, magnetic fluxes change over time around the coil. When another coil is approached around the coil, an alternating voltage is generated in the coil approached by the mutual induction of magnetic flux and current. This degree of interaction is called mutual inductance and the unit is expressed in Henry as well. In addition, the coil is used as the material of the electromagnet due to the nature of stabilizing the change of current, and also has the nature of resonance.

Transformers and electromagnets correspond to electronic components that utilize coil induction. Basically, the transformer uses a phenomenon in which the power supplied to the primary coil is converted by the mutual induction of the primary coil and the secondary coil to occur in the secondary coil. In addition, a device called a rectifier converts power and removes alternating current from the converted power, which also includes a coil as a core component.

In recent years, as the demand for portable digital devices such as smartphones, notebooks or various Bluetooth accessories increases, the demand for adapters used to charge secondary batteries embedded in these devices is also increasing. Adapters are a type of rectifier that converts alternating current into direct current, which also includes coils as key components.

Among electronic equipment including coils, transformers, i.e. transformers, were used, for example, by winding the coils directly on the core in order to produce coils used in the transformer according to the prior art.

As noted above, the Henry's value of the coil depends on the core and the coil wound, i.e. the number and shape of the coil being wound. Therefore, according to the prior art, there is a problem in mass production of coils as electronic components due to the inconvenience of winding the coil directly on the core and the hassle of winding the coil regularly.

1 is a plan view of a transformer using a planar coil according to the prior art.

Referring to FIG. 1, a transformer according to the related art includes a substrate 10 and a circuit board 20, but there is an advantage of reducing the thickness of the transformer, but there is a limit to the number of coils wound and an air core coil. In view of this, there is a manufacturing disadvantage that the interaction is weak and additionally provided with a circuit board.

The flat plate transformer and the assembly method thereof according to an embodiment of the present invention are suitable for the production of electronic components including small and standardized coils by stacking coils without bobbins, and also for insulation processing between coils and between coils and cores. Efficient and effective for fixing the coil to the core using an insulating cover.

In this regard, a flat plate transformer and an assembly method thereof according to an embodiment of the present invention are distinguished from the above-described prior art and disclosed to solve the problems of the prior art.

Korea Patent Publication No. 10-1622333 (2016.05.12.)

The problem to be solved by the present invention is to provide a flat transformer and a method for assembling thereof suitable for assembly and mass production by laminating coils without bobbins.

Another object of the present invention is to provide a flat plate transformer having a structure in which stacked coils are fixed to a core and preventing separation thereof, and a method of assembling the same.

Plate-type transformer according to an embodiment of the present invention, the upper side and the lower side can be separated into two parts; A coil assembly having an input terminal for supplying a power signal, the coil assembly including at least one primary coil stacked around the core; At least one secondary coil having an output terminal for outputting a converted power signal and stacked around the core; And a base having a post surrounding the core, wherein the coils are stacked around the post.

Here, the coil assembly further comprises a shielding coil stacked with the primary coil.

Here, the coil assembly further comprises an insulating layer sandwiched between the primary coil and the shielding coil.

Here, when there are two secondary coils, the coil assembly may be stacked between one secondary coil and the other secondary coil.

Here, the insulating layer is characterized in that laminated between the coil assembly and the secondary side coil.

Here, the secondary coil is characterized in that the coil insulated by the coating.

Here, the core includes a main column in which the coils are stacked, and two wing columns connected to the main column to induce magnetic fluxes generated by the coils, and the main part and the lower part of the upper core due to the two parts. A predetermined gap is formed between the main columns of the core.

Here, the last stacked about the core, and further comprising an insulation cover formed with a projection, wherein the insulation cover is laminated by fixing the protrusions formed inside the insulation cover to the hook formed at the end of the post To prevent the coils from leaving the core and the post.

Here, the upper and lower cores are characterized by being supported by a heat resistant tape so as not to be separated.

Here, the primary coil and / or the secondary coil is characterized in that the laminated around the core in the state wound without a bobbin.

A method of assembling a flat transformer according to an embodiment of the present invention may include: preparing a base having a post into which a core is inserted, as a base which serves to form an outer shape of a core and a transformer; Coupling a base to the lower core such that a post acts as a bobbin while wrapping the core; Stacking the insulated primary and secondary coils around the core and the post; And fixing the separated primary coil and the secondary coil to the core by fitting an insulation cover to the hook formed at the post end.

Here, the step of dividing the core into two parts, further comprising the step of finishing the end of the core by connecting the remaining core to the one core is laminated, forming a predetermined gap between the one core and the remaining core It is characterized by connecting to.

According to the present invention, as the coils without bobbins are laminated, assembly of the coil parts is convenient and suitable for mass production.

In addition, it is possible to fix the stacked coils to the core by using an insulating cover, and to prevent separation.

1 is a plan view of a transformer using a planar coil according to the prior art.
2 is a perspective view of a flat transformer according to an embodiment of the present invention.
3 is a perspective view of the disassembled components in the flat transformer according to an embodiment of the present invention.
4 is a perspective view of the components disassembled in the coil assembly at 3;
5 is a perspective view of the core in FIG. 3.
6 is an exemplary view showing a coil according to an embodiment of the present invention.
FIG. 7 is an exemplary view in which an insulation layer cover and a base are enlarged in FIG. 3.
8 is a cross-sectional view of a flat transformer according to an embodiment of the present invention.
9 is a flow chart of a flat transformer assembly method according to an embodiment of the present invention.

Hereinafter, with reference to the accompanying drawings will be described in detail a preferred embodiment of the plate-type transformer and its assembly method.

Like reference symbols in the drawings denote like elements. In addition, specific structural to functional descriptions of one embodiment of the present invention are only illustrated for the purpose of describing the embodiment according to the present invention, and unless otherwise defined, all terms used herein including technical or scientific terms are used. The terms have the same meaning as commonly understood by one of ordinary skill in the art. Terms such as those defined in the commonly used dictionaries should be construed as having meanings consistent with the meanings in the context of the related art, and are not construed in ideal or excessively formal meanings unless expressly defined herein. It is preferable not to.

Hereinafter, a flat transformer and an assembly method thereof according to an embodiment of the present invention will be described.

2 is an exemplary diagram of a system environment including an apparatus for adjusting the number of pages of a document according to an exemplary embodiment.

2 is a perspective view of a flat transformer according to an embodiment of the present invention.

2, the flat transformer 100 according to an embodiment of the present invention includes a core 110, a coil assembly 120, a secondary coil 130, and a base 140.

The core 110 is configured to be separated into two parts, the upper core 111 and the lower core 112. As a material of the large transformer core 110, a silicon steel sheet having a higher silicon (Si) content than that of general carbon steel or carbon steel may be laminated, but in this case, vortex loss may occur. Therefore, in the present invention, it is preferable that the core 110 of ferrite material is used. Ferrite is a ceramic magnetic material formed by pressing and molding iron powder instead of the iron plate in order to prevent eddy currents caused by the iron plate. In addition, the ferrite core 110 is characterized by low hysteresis loss.

The coil assembly 120 includes an input terminal for supplying a power signal and includes at least one primary coil stacked around the core 110.

The secondary coil 130 includes an output terminal for outputting the converted power signal, and at least one secondary coil is stacked around the core. Referring to FIG. 2, two secondary side coils 130 are depicted in one embodiment.

Base 140 has posts 141 that wrap around core 110. The coil assembly 120 and the secondary side coil 130 including the primary side coils are stacked around the post 141. The post 141 will be described in detail with reference to FIGS. 4 and 7. Base 140 may be implemented with an insulating material. Preferably, the base 140 may be made of a resin material through a mold design. Hereinafter, the disassembled components of the flat transformer 100 will be described in detail with reference to a perspective view depicted.

3 is a perspective view of the disassembled components in the flat transformer according to an embodiment of the present invention.

Referring to FIG. 3, the flat transformer 100 may be assembled with the upper core 111 and the lower core 112 at both ends. In addition, the upper layer core 111 and the lower layer core 112 may be combined so as not to be separated by the heat resistant tape 150. That is, the heat resistant tape 150 serves to support the upper core 111 and the lower core 112 so as not to be separated. Here, the heat resistant tape 150 is a tape made of a material resistant to heat generation of the coil, and is taped around the core 110.

4 is a perspective view of the core in FIG. 3.

Referring to FIG. 4, the core 110 may be formed of two parts, an upper core 111 and a lower core 112. Each of the cores 111 and 112 is connected to a main column 110a and a main column 110a in which the primary coil 121 and the secondary coils 131 and 132 are stacked to induce magnetic flux generated in the coil 111. It includes two wing columns (110b, 110c). The core 110 may form a predetermined gap 113 between the main column 110a of the upper core 111 and the main column 110a of the lower core 112 due to two parts. The gap 113 will be described later.

The base 140 is coupled between the cores 111 and 112. The base forms the outline of the flat transformer 100. Specifically, the main column 110a of the lower layer core 112 is fitted into the through hole inside the base 140 and the post 141 in the upward direction. In addition, the secondary coil 132, the coil assembly 120, the secondary coil 131, and the insulating cover 160 are sequentially stacked on the post in which the main column 110a is fitted. Finally, the main column 110a of the upper core 111 is in contact with the post 141 of the base 140 and the bottom end of the upper core 111 is in contact with the upper end of the lower core 112. Are stacked in order. That is, the upper core 111 processes the finishing of the laminated structure.

FIG. 5 is a perspective view of components disassembled from the coil assembly 120 in FIG. 3.

Referring to FIG. 5, the coil assembly 120 includes at least one primary coil 121, at least two shield coils 122, and at least two insulation layers 123.

When the plurality of primary side coils 121 are provided, there are advantages in that various outputs can be provided to the secondary side coils 131 and 132. The primary coil 121 is preferably made of copper, but is not necessarily limited thereto. Other metals having high conductivity may be used.

6 is an exemplary view showing a coil according to an embodiment of the present invention.

Referring to Figure 6, according to one embodiment of the present invention is depicted a laminated primary coil 121 of the bobbin-free form manufactured by winding the copper wire, the shape of the copper wire wound, the thickness of the copper wire and the like It is not limited to drawing.

The shielding coil 122 performs an electromagnetic shield. Composites containing finely sized conductive fillers in the polymer matrix are suitable as materials for the shielding coil 122.

The insulating layer 123 is stacked between the plurality of primary side coils 121 and the shielding coils 122. The insulating layer 123 is also laminated between the coil assembly 120 and the secondary coils 131 and 132. The insulating layer 123 may be made of a general insulating material through which no current flows, and preferably, a film form. In addition, the role of the insulating layer 122 may be substituted by alcohol, that is, the alcohol is formed by applying and drying the alcohol on the primary coil 121 and the shielding coil 122 to form an alcohol film to perform the role of the insulating layer 122. Can be.

7 is a cross-sectional view of a flat transformer according to an embodiment of the present invention.

Referring to FIG. 7, a gap is formed at a position of the main column 110a where the upper core 111 and the lower core 112 contact each other. The gap 113 serves to increase the amount of magnetic flux by forming an air gap in the middle of the core through which the magnetic flux passes. An epoxy bond for bonding the upper core 111 and the lower core 112 to the gap 113 may be applied. It can be seen that the cross-sectional view shown in FIG. 6 follows the stacking order within the coil assembly 120 of FIG. 5.

Referring again to FIG. 3, when the secondary coils 131 and 132 are two, the coil assembly 120 is preferably stacked between the upper secondary coil 131 and the lower secondary coil 132. Do. The secondary coils 131 and 132 are characterized by being coils insulated by coating. When the upper secondary coil 131 is stacked, the insulating cover 160 is stacked thereon. The insulating cover 160 performs an additional function to the function of the insulating layer 123. A protrusion is formed inside the insulating cover 160.

FIG. 8 is an exemplary view in which an insulation cover and a base are enlarged in FIG. 3.

Referring to FIG. 8, the protrusion 161 formed inside the insulating cover 160 and the hook 142 formed on the side of the post 141 are depicted. The insulation cover 160 includes the cores 121 and 122 and the insulation layers 123 stacked by fixing the protrusions formed inside the insulation cover to the hooks 142 formed at the ends of the posts 141. It can prevent the departure from the post. Hereinafter, a method of assembling the flat transformer 100 according to an embodiment of the present invention will be described.

9 is a flow chart of a flat transformer assembly method according to an embodiment of the present invention.

9, the flat transformer assembly method (S100) includes the steps S110 to S161. Hereinafter, S100 will be described with reference to FIGS. 3 and 9.

First, a base 140 having a post 141 into which the core 110 is fitted is prepared as the base 140 serving to form the core 110 and the outer shape of the transformer (S110).

The through hole in the base 140 post 141 is coupled to the main column 110a of the lower core 112 so that the post 141 acts as a bobbin while surrounding the core 110, particularly the main column 110a (S120). ).

Next, the insulated primary coil 121 and secondary coils 131 and 132 are stacked around the core 110 and the post 141 (S130). The primary coil 121 is stacked in the coil assembly 120, and the secondary coils 131 and 132 are stacked above and below the coil assembly 120, respectively. An insulating layer 123 is stacked together between each stacked element. Referring to FIG. 3, the secondary coil 132, the coil assembly 120, the secondary coil 131, and the insulating cover 160 are stacked in this order.

Next, the insulation cover is fitted to the hook 142 formed at the end of the post 141 to fix and prevent the stacked primary and secondary coils from being separated from the core (S140). Small electronic equipment in which the flat transformer 100 can be used can be moved without being fixed, so that the coil layer formed by the lamination surrounding the core 110 is moved or otherwise misplaced in the core 110 main column 110a. There is a risk of deviation. The problem can be solved by fixing the insulating cover 160 to be finally laminated to the hook 142 at the end of the base 140 and the post 141.

Finally, the core 110 is divided into two parts, and the other cores 111 are connected to one core 112 formed with stacking to finish the termination of the core 110 (S150).

Here, it is characterized in that the connection to form a predetermined gap between one core 112 and the other core 111 (S151). This gap 113 serves to increase the amount of magnetic flux. In addition, an epoxy bond for bonding both cores may be applied to the gap 113 surface.

Thus, according to an embodiment of the present invention, by assembling the coil without the bobbin, the assembly of the coil parts is convenient and suitable for mass production.

In addition, it is possible to fix the stacked coils to the core by using an insulating cover, and to prevent separation.

The foregoing description of the present invention is intended for illustration, and it will be understood by those skilled in the art that the present invention may be easily modified in other specific forms without changing the technical spirit or essential features of the present invention. will be. It is therefore to be understood that the above-described embodiments are illustrative in all aspects and not restrictive. For example, each component described as a single entity may be distributed and implemented, and components described as being distributed may also be implemented in a combined form.

The scope of the present invention is shown by the following claims rather than the above description, and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be construed as being included in the scope of the present invention. do.

100: flat transformer
110: core
110a: main column
110b: wing column
110c: wing column
111: upper core
112: lower core
120: coil assembly
121: primary coil
122: shielding coil
123: insulation layer
131, 132: secondary coil
140: base
141: post
142: hook
150: heat resistant tape
160: insulation cover

Claims (12)

A core detachable into two parts, upper and lower;
A coil assembly having an input terminal for supplying a power signal, the coil assembly including at least one primary coil stacked around the core;
At least one secondary coil having an output terminal for outputting a converted power signal and stacked around the core; And
A base having a post surrounding the core,
And the coils are stacked around the post. The method according to claim 1,
The coil assembly includes:
And a shielding coil stacked together with the primary coil. The method according to claim 2,
The coil assembly includes:
And a insulation layer sandwiched between the primary coil and the shielding coil. The method according to claim 1,
And the coil assembly is laminated between one secondary coil and the other secondary coil when there are two secondary coils. The method of claim 4,
The insulating layer,
And stacked between the coil assembly and the secondary coil. The method according to claim 1,
The secondary coil,
A flat transformer, characterized in that the coil is insulated by covering. The method according to claim 1,
The core comprises:
A main column in which the coils are stacked, and two wing columns connected to the main column to induce magnetic flux generated by the coils,
And the two parts form a predetermined gap between the main column of the upper core and the main column of the lower core. The method according to claim 1,
Lastly laminated with respect to the core, and further comprising an insulating cover formed with a projection,
The insulation cover,
And fixing the protrusions formed inside the insulation cover to hooks formed at the ends of the posts to prevent the coils from being separated from the cores and the posts. The method according to claim 1,
And the upper and lower cores are supported by a heat resistant tape so as not to be separated. The method according to claim 1,
The primary side coil and / or secondary side coil,
A plate-type transformer, characterized in that laminated on the core in the state wound without a bobbin. A base serving to form an outline of a core and a transformer, comprising: preparing a base having a post into which the core is fitted;
Coupling a base to the lower core such that a post acts as a bobbin while wrapping the core;
Stacking the insulated primary and secondary coils around the core and the post; And
And attaching an insulating cover to a hook formed at a post end to fix and prevent the stacked primary and secondary coils from being separated from the core. The method of claim 11,
Dividing the core into two parts, further comprising the step of finishing the termination of the core by connecting the remaining core to one of the core is laminated,
And forming a predetermined gap between the one core and the remaining cores.

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