TWI473126B - 具有分段一次繞組之變壓器 - Google Patents
具有分段一次繞組之變壓器 Download PDFInfo
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- H01F38/023—Adaptations of transformers or inductances for specific applications or functions for non-linear operation of inductances
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
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Description
本案請求美國臨時專利申請案第61/083,717號,申請日2008年7月25日之優先權,該案全文係以引用方式併入此處。
大致上本發明係關於電路,特別係關於變壓器及相關之動力系統。
多年來功率調節電路已經從線性調節器演進為低頻脈寬調變系統,及然後演進為高頻方波換流器。更為晚近已經採用共振換流器來以更輕薄短小更價廉的封裝達成改良效能。
共振換流器是一種採用共振L-C電路來執行功率變換之功率調節系統。通常,共振換流器控制一個或多個開關的操作來施加電壓(或電流)之方波至該共振電路。然後共振電路內部之能量變換成耦接至該換流器輸出端之一負載。
如熟諳技藝人士已知,多種共振換流器之拓樸學為可能,包括升壓模式、降壓模式及降壓-升壓(返馳)及升壓-降壓。多種常見共振換流器拓樸學採用一個或多個變壓器來達成設計目的,諸如阻抗匹配、輸入端與輸出端的絕緣、電磁干擾(EMI)的減低等。本揭示文描述可採用(但非限制性)作為共振換流器中之變壓器之一種變壓器設計。
於至少一個實施例中,一種變壓器包括一核心其具有一第一腳、一第二腳及一第三腳,一分段一次繞組其包括環繞該第一腳之第一匝電性耦接環繞該第三腳之第二匝,及環繞該第二腳之一二次繞組。鏈接該分段一次繞組之第一匝之磁通及鏈接該分段一次繞組之第二匝之磁通係鏈接該二次繞組。
當結合附圖研讀時參考後文一個或多個具體實施例之詳細說明將更明白了解本發明及其較佳使用模式,附圖中:第1圖為根據一個實施例一種共振換流器之高階示意圖;第2A圖為例如於換流器例如第1圖所示之共振換流器中可採用之變壓器之具體實施例之第一剖面圖;第2B圖為沿第2A圖所示線2-2之該變壓器具體實施例之第二剖面圖;第2C圖為示意圖顯示串聯的分段一次繞組之各匝;第2D圖為示意圖顯示並聯的分段一次繞組之各匝;第3圖為根據一個實施例製造變壓器之實例方法之高階邏輯流程圖;第4A圖為根據一個實施例耦接至一動力系統之一外部AC/DC換流器之高階示意圖;及第4B圖為根據一個實施例耦接至一動力系統之一內部AC/DC換流器之高階示意圖。
現在參考附圖及特別係參考第1圖,顯示根據一個實施例包括變壓器120之共振換流器100之一實例之高階示意圖。如圖所示,於變壓器120之一次側,共振換流器100包括DC電壓源V_link 102,其可藉任何適當變壓源提供。於多項共通應用中,諸如家用電器、電腦及其它消費性電子裝置、及螢光燈穩壓器中,V_link 102具有約150VDC至400VDC之電壓,例如可藉AC市電電源(主電源)之整流器提供。於此等應用中,由V_link 102所提供之電力選擇性地進一步施加有功率因數校正。為求方便敘述,V_link 102之正端子於此處稱作為節點A,而V_link 102之負端子於此處稱作為節點B。
一對切換元件諸如場效電晶體(FET)104a、104b係以半橋跨V_link 102耦接來提供期望的電壓波形諸如方波。FET 104a與104b之切換以及電壓波形(及相關之電流波形)係藉閘極驅動電路106控制。於多項應用中,閘極驅動電路106係以互補方式操作FET 104a及104b,表示當FET 104a為導通(on)時,FET 104b為關斷(off),及反之亦然。
與各個FET 104a、104b並聯耦接者為個別寄生電容器C_par 108a或C_par 108b分路該等切換元件中之相對應者。如此C_par 108a係耦接於節點A與FET 104a與104b間之中間節點D間,而C_par 108b係耦接於節點D與節點B間。
一對共振電容器C_res 110a及C_res 110b進一步跨節點A與節點B間之V_link 102耦接。C_res 110a及C_res 110b之數值經選定來決定共振換流器100之期望的共振頻率。C_res 110a及C_res 110b係共同耦接於節點E。
如技藝界已知,變壓器120包括一一次繞組及一二次繞組,其匝數比為控制跨二次繞組感應電壓之一項因素。於第1圖所示相當電路中,變壓器120係以耦合電感L_cpld 124及洩漏電感L_lkg 122為其特徵,二者連同C_res 110a及C_res 110b形成共振換流器100之共振電路。如後文就第2A-2B圖進一步說明如下,耦合電感L_cpld 124及洩漏電感L_lkg 122較佳並未以分開的電感器組件實施,反而單純為藉此種組成決定之變壓器120之特性。於此種實施例中,變壓器120之一次繞組係耦接於節點D與節點E間。
變壓器120之二次繞組具有終端定義為節點F及節點G係耦接至一經濾波之全波整流器。經濾波之全波整流器包括四個二極體130a、130b、130c及130d,此處二極體130a具有耦接至節點F之一輸入端及耦接至第一輸出節點H之一輸出端,二極體130b具有耦接至節點G之輸入端及耦接至第一輸出節點C之輸出端,二極體130c具有耦接至第二輸出節點J之一輸入端及耦接至節點F之一輸出端,及二極體130d具有耦接至第二輸出節點J之一輸入端及耦接至節點G之一輸出端。經濾波之全波整流器進一步包括跨輸出節點H及J耦接至一輸出電容器C_out 134來濾波或平順化由全波整流器所形成之脈動式直流電源(例如20VDC)中之紋波。紋波幅度例如係依據輸入電壓振幅及頻率、濾波器電容、及跨輸出節點H及J耦接的負載電阻R_load 136決定。
現在參考第2A圖,顯示例如於換流器內例如第1圖之共振換流器100中可採用之變壓器120之具體實施例之剖面圖。於該具體實施例中,變壓器120具有高導磁率之核心(例如鐵心)其具有至少外第一腳202a及第三腳202c及設置於該第一腳202a與第三腳202c間之一內第二腳202b。核心例如可為由第一E核心剖面200a及第二E核心剖面200b所形成之商業上可購得的EE核心。另外,核心可為由E核心剖面與I核心剖面(圖中未顯示)所形成之商業上可購得之EI核心。如第2B圖所示,其為沿第2A圖之線2-2之剖面圖,第一E核心剖面200a(及第二E核心剖面200b)及其各腳202共通具有(但非要求具有)方形或矩形橫截面。
進一步,如第2A圖所示,當變壓器120之核心組裝時,第二腳202b具有於其中介於核心剖面間所形成之一氣隙204b,如後文討論,該氣隙定義變壓器120的所謂的洩漏電感。此外,第一腳202a及第三腳202c選擇性地具有個別氣隙204a及204c形成於其中介於核心剖面間。於其中第一腳202a及第三腳202c包括氣隙204a及204c之實施例中,氣隙204a及204c典型地係小於第二腳202b之氣隙204b。
第一、第二及第三腳202a、202b及202c各自載有個別的筒管206a、206b及206c。筒管206a、206b及206c例如可由熱塑性塑膠(例如聚伸丁基對苯二甲酸酯(PBT))或熱固性塑膠(例如酚系塑膠)製成。各筒管206a、206b或206c具有一核心殼體部208用於攜載形成一次繞組或二次繞組之導電線圈,及一核心間隔部210其維持線圈與核心之物理隔開及維持線圈及核心與外部變壓器機殼(若有)的物理隔開。
於該具體實施例中,第二筒管206b攜載二次繞組212b,二次繞組212b較佳但非必要呈單層捲繞於第二筒管206b上。於多個共通應用中,其中變壓器120為降壓變壓器,其中二次繞組212b具有比一次繞組更低的電壓及更高的電流,二次繞組212b係由比一次繞組更大的繞線所組成。進一步較佳二次繞組212b係由多股辮編線形成來減少趨膚效應的損耗及鄰近效應的損耗。
於所示具體例中,第一筒管206a及第三筒管206c攜載分段一次繞組之個別部分212a及212c,各部分係電連結,如第2C圖所示之串聯或如第2D圖所示之並聯。如前文說明,一次繞組通常具有比二次繞組更多匝數及較低電流,允許於一次繞組中使用比二次繞組更小直徑的繞線。經由如第2D圖所示,並聯兩個一次繞組部212a及212c可更進一步縮小繞線直徑的要求,表示各繞組部212a及212c只攜載總一次繞組電流的一部分。一次繞組可由使用辮編線獲益,但有鑑於較高匝數及(若適用時)其並聯組成,並不要求繞線為絞合股線。
與習知分段一次繞組的組成相反,一次繞組部分212a及212c具有不等的匝數。於多個實施例中,匝數相當接近差異例如約為1%至20%,及特別約10%。第2A圖顯示具有比部分212c更大匝數之部分212a;但須了解哪一個部分212a及212c具有較高匝數並無特殊限制。
分段一次繞組之串聯組成及並聯組成間之選擇係取決於應用。於並聯組成中,分段一次繞組之部分212a及212c具有相等電壓,但產生不同通量。此種情況下,具有較少匝數之部分212c產生較多通量係攜載比部分212a更大量的電流;但當通過部分212a與212c的電流加總時,流經分段一次繞組各部分之電流係小於利用串聯組成時之電流,如此可採用較小規格的繞線。於串聯組成中,分段一次繞組之部分212a及212c攜載相等電流,但其間具有不同電壓。於此種情況下,有較多匝數部分212a產生較大通量,維持比部分212c更高的電壓。如此,有較高電流(因而需要較大直徑繞線)及較低電壓之實施例將有利於並聯,而有較低電流及較高電壓(因而需要較厚的絕緣)之實施例將有利於串聯。也須注意特定尺寸限制及構造考量諸如繞線類型、容易終結及軟焊、及筒管形狀及材料等考量全部皆促成選用一種構造優於另一種構造。
當安裝於核心上時,一次繞組與二次繞組物理上分隔,有助於絕緣障體214a及214b分別置放於第一腳與第二腳202a與202b間及第二腳與第三腳202b與202c間。一次繞組及二次繞組之物理分隔也減低一次繞組與二次繞組間之電容,因而滿意地減少跨變壓器120之電磁干擾(EMI)耦合。
當藉施加電流供電至分段一次繞組時,一次繞組之鏈接部212a及212c分別所得磁通220a及220b之幅度係與繞線匝數成反比。如此,部分212c之磁通220b係大於部分212a之磁通220a。如圖所示,一次繞組之部分212a及212c之相位情況使得磁通220a及220b加入第二腳202b,鏈接二次繞組212b。由較低匝數的二次繞組212b所產生之額外磁通222係於核心外環循環,與部分212c之磁通220b反向俾便補償一次繞組部分212a所供應之磁通的短缺。此種差異磁通222並未流經第二腳202b,且未鏈接二次繞組212b,產生經良好控制的洩漏電感124。
如此處使用,「洩漏電感」一詞用來符合工業標準。但須注意,於所示具體實施例中,本未經耦合的「洩漏電感」的主要分量並非洩漏變壓器核心外側進入周圍空間的磁通,反而由於蓄意設計選擇的結果係來自二次繞組212b重新路由通過的磁通,該設計係用來減少一次繞組與二次繞組之磁耦合。洩漏電感124之幅度只依據核心幾何形狀、分段一次繞組之二部分212a、212c間之匝數差、及第一腳202a及第三腳202c中之氣隙204a、204c(通常小型)決定,但未可察覺地依據繞組相對位置及形狀決定,如一般真正洩漏電感的情況。結果,洩漏電感124之幅度及如此二次繞組212b之電流於製造過程中容易控制。
耦合(或磁化)電感122主要係由中腳之氣隙決定,於變壓器120製造中該氣隙通常維持緊密公差。
現在參考第3圖,顯示根據一個實施例,變壓器120之製造方法實例之高階邏輯流程圖。至於邏輯流程圖,可同時進行至少部分所示步驟或以所示順序以外之任一種順序執行。
該方法始於方塊300然後前進至方塊302,顯示提供具有至少三支腳的一核心。如前述,核心例如可為EE鐵心或EI鐵心。於方塊304,一次繞組之部分212a及212c分別係以第一筒管206a及第三筒管206c為中心繞線。部分212a及212c之匝數不等,該匝數經選擇來決定變壓器120之洩漏電感L_lkg 124之期望值。此外,於方塊306,二次繞組212b係以第二筒管206b為中心繞線。然後一次繞組及二次繞組可選擇性接受清漆浸漬處理來將繞線相對於筒管206a、206b及206c定位。
如方塊308指示,第一、第二及第三筒管206a、206b及206c分別置放於第一、第二及第三腳202a、202b及202c上。筒管206a、206b及206c係以相對方向性安裝來確保如第2A圖所示,第二腳202b之磁通220a及220b為加成。一次繞組及二次繞組藉安裝間隙絕緣障體214a及214b彼此絕緣,如方塊310所示。此外,一次繞組部分212a及212c係並聯電耦接,如方塊312指示。變壓器120選擇性地封裝於外部殼體。然後第3圖所示處理程序結束於方塊314。
現在參考第4A-4B圖,顯示動力系統之替代實施例之高階示意圖,該系統可為利用電力的任一類系統。於所示各具體實施例中,動力系統400係電連結換流器(或電源供應器)402且由換流器402接收電力,該換流器於多個共通實施例中為AC/DC換流器,諸如第1圖所示之共振換流器或其它類型換流器。換流器402包括具有如此處所述分段一次繞組之變壓器。如第4A圖所示,如目前常見於可攜式電子裝置諸如膝上型手機、行動電話、可攜式音樂播放器等,換流器402可位於動力系統400外部。另外,如第4B圖所示,如目前常見於桌上型個人電腦系統,換流器402可實施於動力系統400的機殼內部。
已經說明適合用於例如換流器的變壓器設計。該變壓器設計提供:
1.一次繞組與二次繞組間的絕緣,滿足多項安全標準;
2.精確電壓比,於給定的低耦合係數時,其非必然與一次對二次匝數比相關;
3.具有經控制數值之高洩漏電感;
4.精簡設計其尺寸符合維度限制。
雖然已經說明一個或多個較佳實施例,但熟諳技藝人士須了解可未悖離如後文說明之申請專利範圍之精髓及範圍,就形式及細節上做出多項變化。
2‧‧‧視線
100‧‧‧共振換流器
102‧‧‧DC電壓源V_link
104、104a-b‧‧‧場效電晶體、TFT
106‧‧‧閘極驅動電路
108、108a-b‧‧‧寄生電容器C_par
110、110a-b‧‧‧共振電容器C_res
120‧‧‧變壓器
122‧‧‧洩漏電感L_lkg
124‧‧‧耦合電感L_cpld
130、130a-d‧‧‧二極體
134‧‧‧輸出電容器C_out
136‧‧‧負載電阻R_load
200、200a-b‧‧‧E核心區段
202、202a-c‧‧‧腳
204、204a-c‧‧‧氣隙
206、206a-c‧‧‧筒管
208‧‧‧核心殼體部
210‧‧‧核心間隔部
212‧‧‧繞組
212a、212c‧‧‧一次繞組部
212b‧‧‧二次繞組部
214、214a-b‧‧‧絕緣障體
220、220a-b‧‧‧磁通
222‧‧‧額外磁通
300-314‧‧‧方塊
400‧‧‧動力系統
402‧‧‧換流器、電源供應器
第1圖為根據一個實施例一種共振換流器之高階示意圖;第2A圖為例如於換流器例如第1圖所示之共振換流器中可採用之變壓器之具體實施例之第一剖面圖;第2B圖為沿第2A圖所示線2-2之該變壓器具體實施例之第二剖面圖;第2C圖為示意圖顯示串聯的分段一次繞組之各匝;第2D圖為示意圖顯示並聯的分段一次繞組之各匝;第3圖為根據一個實施例製造變壓器之實例方法之高階邏輯流程圖;第4A圖為根據一個實施例耦接至一動力系統之一外部AC/DC換流器之高階示意圖;及第4B圖為根據一個實施例耦接至一動力系統之一內部AC/DC換流器之高階示意圖。
2...視線
120...變壓器
200a...第一E核心剖面
200b...第二E核心剖面
202a...第一腳
202b...第二腳
202c...第三腳
204a...氣隙
204b...氣隙
204c...氣隙
206a、206b、206c...筒管
208...核心殼體部
210...核心間隔部
212a、212c...一次繞組部
212b...二次繞組
214a、214b...絕緣障體
220a、220b...磁通
222...額外磁通
Claims (23)
- 一種變壓器,包含:具有一第一腳、一第二腳及一第三腳之一鐵心,其中至少該第二腳中具有一氣隙;包括與環繞該第三腳之多個第二匝電氣耦接的環繞該第一腳之多個第一匝之一分段一次繞組;以及環繞該第二腳之一個二次繞組,其中鏈接該分段一次繞組之第一匝之磁通及鏈接該分段一次繞組之第二匝之磁通於該第二腳中相加成且鏈接該二次繞組。
- 如申請專利範圍第1項之變壓器,其中該分段一次繞組之第一匝及第二匝係並聯電連接。
- 如申請專利範圍第1項之變壓器,其中該分段一次繞組之第一匝及第二匝係串聯電連接。
- 如申請專利範圍第1項之變壓器,其中該等第一匝之第一匝數係與該等第二匝之第二匝數不同。
- 如申請專利範圍第4項之變壓器,其中該二次繞組之第三匝數係小於該第一匝數及該第二匝數。
- 如申請專利範圍第1項之變壓器,其中:該氣隙為一第一氣隙;及包括該第一腳及該第二腳之一集合中之至少一者具有一第二氣隙於其中。
- 如申請專利範圍第6項之變壓器,其中該第一氣隙係大於該第二氣隙。
- 如申請專利範圍第1項之變壓器,其進一步包含設置於 該等第一匝與該二次繞組間及設置於該等第二匝與該二次繞組間之絕緣部。
- 如申請專利範圍第1項之變壓器,其進一步包含分別設置於該第一腳、第二腳及第三腳上之第一筒管、第二筒管及第三筒管,其中:該等第一匝係環繞該第一筒管捲繞;該等第二匝係環繞該第三筒管捲繞;及該二次繞組係環繞該第二筒管捲繞。
- 如申請專利範圍第1項之變壓器,其中該第二腳為設置於該第一腳與第三腳間之一中間腳。
- 如申請專利範圍第1項之變壓器,其中該鐵心包含一EE型鐵心。
- 如申請專利範圍第1項之變壓器,其中:該第二腳為設置於該第一腳與該第三腳之間的一中間腳;該等第一匝之一第一匝數與該等第二匝之一第二匝數不同;以及該第二繞組之一第三匝數小於該第一匝數及該第二匝數。
- 如申請專利範圍第12項之變壓器,其中:該氣隙為一第一氣隙;及包括該第一腳及該第二腳之一集合中之至少一者具有一第二氣隙於其中。
- 一種轉換器,其包括如申請專利範圍第1項之變壓器。
- 一種系統,包含:包括一變壓器之一電源供應器,該變壓器具有:具有一第一腳、一第二腳及一第三腳之一鐵心,其中至少該第二腳中具有一氣隙;包括與環繞該第三腳之多個第二匝電氣耦接的環繞該第一腳之多個第一匝之一分段一次繞組;及環繞該第二腳之一個二次繞組,其中鏈接該分段一次繞組之第一匝之磁通及鏈接該分段一次繞組之第二匝之磁通於該第二腳中相加成且鏈接該二次繞組;以及電氣耦接來接收來自該電源供應器之電力之一受電系統。
- 如申請專利範圍第15項之系統,其中:該受電系統包括一殼體;該電源供應器係位於該殼體內部。
- 如申請專利範圍第15項之系統,其中:該受電系統包括一殼體;該電源供應器係位於該殼體外部。
- 如申請專利範圍第15項之系統,其中該分段一次繞組之該等第一匝及該等第二匝係並聯電連接。
- 如申請專利範圍第15項之系統,其中該分段一次繞組之該等第一匝及該等第二匝係串聯電連接。
- 如申請專利範圍第15項之系統,其中該等第一匝之第一 匝數係與該等第二匝之第二匝數不同。
- 如申請專利範圍第20項之系統,其中該二次繞組之一第三匝數係小於該第一匝數及該第二匝數。
- 如申請專利範圍第15項之系統,其中該第二腳為設置於該第一腳與該第三腳間之一中間腳。
- 如申請專利範圍第15項之系統,其中:該第二腳為設置於該第一腳與該第三腳之間的一中間腳;該等第一匝之一第一匝數與該等第二匝之一第二匝數不同;以及該第二繞組之一第三匝數小於該第一匝數及該第二匝數。
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CN101635524A (zh) | 2010-01-27 |
EP2313965A1 (en) | 2011-04-27 |
TW201009358A (en) | 2010-03-01 |
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CN101635524B (zh) | 2014-02-19 |
CN101651424B (zh) | 2014-03-12 |
US20100020573A1 (en) | 2010-01-28 |
CN102165679B (zh) | 2014-07-02 |
TW201106603A (en) | 2011-02-16 |
US8279628B2 (en) | 2012-10-02 |
TW201012040A (en) | 2010-03-16 |
CN101651424A (zh) | 2010-02-17 |
US20100020579A1 (en) | 2010-01-28 |
EP2313965A4 (en) | 2015-11-04 |
US8553430B2 (en) | 2013-10-08 |
US8330434B2 (en) | 2012-12-11 |
TWI469487B (zh) | 2015-01-11 |
CN101635512B (zh) | 2014-03-12 |
CN102165679A (zh) | 2011-08-24 |
CN101707121B (zh) | 2013-05-08 |
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