TWM446964U - Edge-winding type winding transformer - Google Patents

Description

Edge wound winding transformer

The present invention relates to a winding transformer, and more particularly to a side winding type winding transformer.

For power converters (eg, computer power supplies or switched power supplies), how to increase power density, reduce size, and increase switching frequency (switching frequency) is a concern for designers of power converters. Increasing the switching frequency can reduce the size of, for example, transformers and filters, but switching losses can adversely affect high frequency operation. In order to reduce switching losses, resonant switching techniques have been proposed.

In general, an LLC resonant power converter includes a controller with a metal oxide semiconductor field effect transistor (MOSFET), an LLC resonant network, and a rectifier network. The controller alternately switches the two MOSFETs by means of pulse frequency modulation (PFM), and changes the operating frequency as the load changes, adjusting the output voltage Vout. The LLC resonant network includes two resonant inductors (Lr and Lm) and one resonant capacitor (Cr). The LLC resonant power converter features zero voltage switching (ZVS) and low voltage stress on the device, making it ideal for applications requiring high efficiency and high power supplies. With the wide application of LLC resonant power converters, the design of LLC transformers for LLC resonant power converters has received increasing attention. Known for LLC transformers used in LLC resonant power converters, the magnetic components Lr and Lm are usually integrated into one transformer. By using the leakage inductance (leakage inductance) of the transformer as Lr and the magnetic inductance (magnetizing inductance) of the transformer as Lm, the number of magnetic elements can be reduced.

Conventional winding transformers have a fixed iron core with a primary (also called once) and secondary (also called secondary) coil wound. The winding of the coil is usually coaxial with the primary and secondary coils. The relationship is wound around the same core, one of which is located on the inner ring and the other is located on the outer ring. The primary and secondary coils are electrically separated from each other and insulated from each other. In this way, the winding transformer, the primary winding and The secondary coils have a better coupling density at the beginning and therefore have a smaller leakage inductance. In general, the amount of magnetic inductance (magnetizing inductance) of LLC is 3 to 7 times the amount of leakage inductance (magnetic leakage inductance), and the leakage inductance value is usually required to be large. In other words, the LLC transformer is applied to the LLC resonant power converter. The coupling density between the primary side and the secondary side of the transformer should be reduced to achieve a large leakage inductance.

On the other hand, when the winding transformer of the inner and outer windings is used in operation, the coil located in the inner ring also has a problem that heat dissipation is not easy. Therefore, the LLC transformer designed for the LLC resonant power converter needs to focus on designing the leakage inductance and magnetic inductance of the transformer, and designing the winding method of the primary side and the secondary side of the transformer.

This creation proposes a side-wound winding transformer, which has the advantages of convenient adjustment of leakage inductance, good heat dissipation effect, space saving, reduction of copper loss and iron loss, and improvement of electrical and efficiency effects.

An embodiment of a side-wound winding transformer proposed by the present invention is constructed Included: at least two upright juxtaposed iron cores, and first and second windings respectively wound around the two upright juxtaposed iron cores, the first winding and the second winding are respectively different secondary side coils, in the An insulating layer is disposed between a winding and the second winding; and the other core of the second winding is disposed on a side of one of the cores around which the first winding is disposed to form a side winding type The winding transformer is used to achieve the aforementioned effects.

An embodiment of the edge-wound winding transformer proposed by the present invention comprises: an upright side-by-side side iron core and a right side iron core, the left side iron core is provided with at least a first winding, and the right side iron core is wound with a second winding. The first winding and the second winding are respectively coils of different secondary sides, and an insulating layer is disposed between the first winding and the second winding.

Another embodiment of the edge wound winding transformer according to the present invention comprises: an upright side-by-side left core and a right core, the left core being wound with a first winding on the inner layer and a second outer layer Winding, the right iron core is wound with a second winding, the first winding and the second winding are respectively different secondary coils, an insulating layer is disposed between the first winding and the second winding, and the first and second windings are The system is either a copper wire, a copper foil or an enameled wire.

Another embodiment of the edge wound winding transformer according to the present invention comprises: three upright side-by-side side iron cores, an intermediate iron core and a right iron core, wherein the middle iron core is at least wound with the first winding, At least one of the left core and the right core is wound around a second winding, the first winding and the second winding being coils of different secondary sides, respectively, and an insulating layer is disposed between the first winding and the second winding.

Another embodiment of a side-wound winding transformer according to the present invention, a package The utility model comprises: three upright side-by-side iron cores, an intermediate iron core and a right iron core, wherein the middle iron core is wound with a first winding on the inner layer and a second winding on the outer layer, at least one of the left iron core and the right iron core One is wound around the second winding, and the first winding and the second winding are respectively coils of different secondary sides, and an insulating layer is disposed between the first winding and the second winding.

An embodiment of the edge wound winding transformer according to the present invention, wherein the left core and the right core are respectively wound with a second winding, and the second windings wound around the left core and the right core are connected in series with each other.

An embodiment of the edge wound winding transformer according to the present invention, wherein the left core and the right core are respectively wound with a second winding, and the second windings wound around the left core and the right core are connected in parallel with each other.

An embodiment of the edge wound winding transformer according to the present invention, wherein the left iron core and the right iron core are respectively wound with a second winding, and are wound around the second iron core, the right iron core and the middle iron core. The windings are connected in series.

An embodiment of the edge wound winding transformer according to the present invention, wherein the left side core and the right side iron core are respectively wound with the second winding, and the second windings wound around the left side core and the right side core are connected in parallel with each other and then And in series with the second winding wound around the intermediate core.

Combining the above-mentioned creations, it can be understood that the winding-wound transformer of the present invention forms a side-wound winding transformer by means of winding the first winding and the second winding respectively in at least two upright side-by-side iron cores. Basic construction, other embodiment changes based on this basic structure, with three upright juxtaposed irons The core, and the change of a single-layer coil or a double-layer coil in one of the cores, completes a side-wound winding transformer, and can obtain the following effects.

1. Using the edge-wound structure, it can reduce iron loss and copper loss, improve electrical and efficiency.

2. Using the side-wound construction, the same wire frame and core are more powerful than ordinary winding transformers.

3. Using the side-wound structure, there is a large airflow gap between the coils of the adjacent upright juxtaposed cores, which can improve the heat dissipation effect of the transformer, reduce the loss, and improve the utilization of the transformer.

4. Using the side-wound configuration, it is possible to adjust the airflow gap between any two adjacent upright juxtaposed cores, and has the effect of conveniently adjusting the leakage inductance.

5. Using the edge-wound configuration, the inductance and leakage inductance can be integrated into one, which saves space occupied by the circuit when applied to the LLC transformer.

Other functions and embodiments of the present invention will be described below in conjunction with the drawings.

An embodiment of the side-wound winding transformer proposed by the present invention comprises: at least two upright juxtaposed iron cores, and first and second windings respectively wound around the two upright juxtaposed iron cores, The first winding and the second winding are respectively coils of different secondary sides (primary side or secondary side), and an insulating layer is disposed between the first winding and the second winding; The side of the iron core of the winding is provided with another iron core around which the second winding is arranged, which is convenient for forming Adjusting the leakage inductance, the heat dissipation effect is good, the space is saved, the copper loss and the iron loss can be reduced, and the edge winding type winding transformer which can improve various functions such as electric power and efficiency can be improved. According to the configuration of this embodiment, the "edge winding transformer" of the present invention also has the following several variations, and the embodiments are respectively constructed as follows with the drawings.

An embodiment of the edge-wound winding transformer proposed by the present invention, as shown in FIG. 1, includes: an upright side-by-side left core 10L and a right core 10R, and a left core 10L at least a winding C1, the right core 10R is wound around a second winding C2, and the first winding C1 and the second winding C2 are respectively different secondary (primary or secondary) coils, at the first winding C1 and the second winding An insulating layer 20 is disposed between C2, and the first winding C1 or the second winding C2 may be any one of copper wire, copper foil or enameled wire.

Another embodiment of the edge-wound winding transformer according to the present invention, as shown in "Fig. 2", comprises: an upright side-by-side left core 10L and a right core 10R, and a left core 10L is located around The first winding C1 of the inner layer and the second winding C2 of the outer layer, the right core 10R is wound around the second winding C2, and the first winding C1 and the second winding C2 are respectively coils of different secondary sides (primary side or secondary) Side), an insulating layer 20 is provided between the first winding C1 and the second winding C2, in other words, if the first winding C1 is the primary side coil of the winding transformer, the second winding C2 is the secondary side coil of the winding transformer ,vice versa.

Another embodiment of the edge wound winding transformer according to the present invention, as shown in "Fig. 3", comprises: three upright side-by-side iron cores 10L, an intermediate core 10C and a right core 10R, in the middle The iron core 10C is at least wound around the first At least one of the winding C1, the left core 10L and the right core 10R is wound around the second winding C2. In other words, one of the embodiments only winds the second winding C2 on the left core 10L, and the other embodiment only In the other embodiment, the second winding C2 is wound around the right core 10R. In another embodiment, the second winding is wound around the left core 10L and the right core 10R (see "Fig. 3"), the first winding C1 and the first winding The two windings C2 are respectively coils (primary side or secondary side) of different secondary sides, and an insulating layer 20 is provided between the first winding C1 and the second winding C2.

Another embodiment of the edge wound winding transformer according to the present invention, as shown in FIG. 4, includes: three vertically aligned left iron cores 10L, an intermediate iron core 10C, and a right iron core 10R. The iron core 10C is wound with a first winding C1 located at the inner layer and a second winding C2 at the outer layer, and at least one of the left side core 10L and the right side core 10R is wound around the second winding C2, in other words, one of them In the embodiment, only the second winding C2 is wound around the left core 10L. In another embodiment, the second winding C2 is wound only on the right core 10R, and in another embodiment, the left core 10L and the right core 10R are wound. a second winding (see FIG. 4) is provided. The first winding C1 and the second winding C2 are respectively coils of different secondary sides, and an insulating layer 20 is disposed between the first winding C1 and the second winding C2. That is, if the first winding C1 is the primary side coil of the winding transformer, the second winding C2 is the secondary side coil of the winding transformer, and vice versa.

The first winding C1 and the second winding C2 may be any one of copper wire, copper foil or enamel wire; the first winding C1 and the second winding C2 are respectively different secondary windings, in other words, the first winding C1 Winding transformer The primary side coil, the second winding C2 is the secondary side coil of the winding transformer. Basically, the number of turns of the first winding C1 and the second winding C2 can be determined according to the specification and output power of the transformer, and any coil is in any The number of layers to be wound around the iron core is not limited to a single layer, and may be a single layer or a multilayer structure depending on the specifications of the transformer.

The foregoing insulating layer 20 between the first winding C1 and the second winding C2 may be an insulating tape or an insulating member made of other insulating materials, which will be described in detail below in conjunction with the embodiments.

The edge-wound winding transformer proposed in the present invention can integrate the inductance and the leakage inductance, and can save the space occupied by the circuit when applied to the LLC transformer. On the other hand, the edge-wound winding transformer proposed in the present invention In an embodiment having three upright side-by-side iron cores 10L, an intermediate core 10C and a right core 10R, the second winding C2 can also be used in conjunction with an LLC transformer in the circuit design of the LLC resonant power converter. Different ways of electrical connection in series or in parallel are described below.

In an embodiment having three vertically aligned left iron cores 10L, intermediate iron cores 10C and right iron cores 10R, an electrical connection manner of the second windings C2 is as shown in the equivalent circuit diagram of "5-1". The second winding C2 wound around the left core 10L and the right core 10R is connected in series; the other electrical connection is implemented as shown in the equivalent circuit diagram of FIG. 5-2, in which The left iron core 10L and the second winding C2 of the right iron core 10R are connected in parallel with each other.

In the left side iron core 10L with three upright juxtapositions, the intermediate iron core 10C and In the embodiment of the right core 10R, when the intermediate core 10C is wound around the first winding C1 located in the inner layer and the second winding C2 located in the outer layer, an electrical connection manner of the second winding C2 is as follows: In the equivalent circuit diagram of Fig. 3, the second winding C2 wound around the left core 10L, the right core 10R, and the intermediate core 10C are connected in series; the other electrical connection is implemented, for example, "5-4". The equivalent circuit diagram is shown in which the second winding C2 wound around the left core 10L and the right core 10R is connected in parallel with each other and then connected in series with the second winding C2 wound around the intermediate core 10C.

According to the edge winding type winding transformer of the present invention, an embodiment in which three vertical side cores 10L, an intermediate iron core 10C and a right iron core 10R are juxtaposed therein is exemplified, and a specific one will be disclosed below with reference to the drawings. The structural examples are explained below.

A side-wound wound transformer as shown in Figure 6 includes: Two butted E-shaped cores 30A and 30B, the core material can be made of oxyiron material, and the two E-shaped cores 30A and 30B which are butted together form a three-sided iron core 10L and an intermediate iron. The structure of the core 10C and the right core 10R is not limited to such an E-shaped core, and other cores such as an I-type, a T-shape or a U-shape may be used.

A winding seat, which is a plastic molding component, can be used as the above-mentioned insulator 20. The winding seat comprises: a left winding frame 40L, an intermediate winding frame 40C and a right winding frame 40R, a left winding frame 40L, and an intermediate winding. The frame 40C and the right bobbin 40R are both tubular elements which can be respectively placed on the left side iron core 10L and the intermediate iron. The outer periphery of the core 10C and the right core 10R, and thus the main structure of the edge-wound winding transformer with the E-shaped cores 30A and 30B (see "Fig. 7"), wherein the left winding frame 40L, the middle winding The wire frame 40C and the right winder frame 40R can define a winding space for the first winding C1 and the second winding C2 to be disposed, and a top surface 41 is extended on both sides of the top end of the intermediate winding frame 40C to prevent The first winding C1 and/or the second winding C2 are disengaged, and a plurality of terminal pins 42 are disposed on both sides of the bottom end of the intermediate bobbin 40C, and between the first winding C1 and the second winding C2, The insulating layer 20 (using an insulating tape) is finally coated with a layer 20 (using an insulating tape) on the periphery of the edge-wound winding transformer, so that it can be constructed as shown in Fig. 8.

Although the present invention has been disclosed above through the above embodiments, it is not intended to limit the creation of the present invention. Anyone skilled in the art can make some changes and refinements without departing from the spirit and scope of the present creation. The scope of patent protection is subject to the terms of the claims attached to this specification.

10C‧‧‧ intermediate core

10L‧‧‧left core

10R‧‧‧right core

20‧‧‧Insulation

30A‧‧‧E core

30B‧‧‧E core

40L‧‧‧left winding frame

40C‧‧‧Intermediate Winding Rack

40R‧‧‧Right bobbin

41‧‧‧檐

42‧‧‧Wiring pins

C1‧‧‧First winding

C2‧‧‧second winding

Fig. 1 is an embodiment of the present invention, showing a schematic structural view of two vertically aligned left iron cores, right iron cores, first windings and second windings.

2 is an embodiment of the present invention, showing a schematic structural view of two vertically aligned left iron cores, a right iron core, a first winding and a second winding, wherein the inner layer of the left iron core is the outer layer of the first winding Second winding.

Fig. 3 is an embodiment of the present invention, showing a schematic structural view of three vertically aligned left iron cores, intermediate iron cores, right iron cores, first windings and second windings.

Figure 4 is an embodiment of the present invention, showing a schematic view of three vertical juxtaposed side iron cores, a middle iron core, a right iron core, a first winding and a second winding, the inner core of the middle core being the first The outer layer of the winding is a second winding.

Figures 5-1 to 5-2 are an embodiment of the present invention, shown in an embodiment having three upright juxtaposed iron cores, respectively wound around a second winding of the left and right iron cores An equivalent circuit diagram.

Figures 5-3 to 5-4 are an embodiment of the present invention, shown in an embodiment having three upright juxtaposed cores, respectively wound around the left core, the middle core and the right core An equivalent circuit diagram of the second winding.

Fig. 6 is a view showing an embodiment of the present invention showing the shape of an element for composing three upright juxtaposed iron cores and a combination thereof.

Fig. 7 is a combination view showing the construction of the embodiment of Fig. 6, showing the construction of the components for composing the three upright juxtaposed iron cores.

Figure 8 is a construction of an embodiment of the present invention, showing the core of Figure 6 in a winding The outline of the package is completed after the coil is set.

10C‧‧‧ intermediate core

10L‧‧‧left core

10R‧‧‧right core

30A‧‧‧E core

30B‧‧‧E core

40L‧‧‧left winding frame

40C‧‧‧Intermediate Winding Rack

40R‧‧‧Right bobbin

41‧‧‧檐

42‧‧‧Wiring pins

Claims (11)

An edge wound winding transformer comprising: at least two upright juxtaposed iron cores; and a first winding and a second winding respectively wound around the two upright juxtaposed iron cores, the first winding and the first winding The second windings are respectively coils of different secondary sides, and an insulating layer is disposed between the first winding and the second winding. The edge wound winding transformer of claim 1, wherein one of the two upright juxtaposed iron cores is provided with the first winding at the inner layer and the second at the outer layer. The winding, the other core is wound around the second winding, and the first winding and the second winding are respectively coils of different secondary sides. The edge-wound winding transformer according to claim 1, wherein the iron cores are upright and juxtaposed, comprising: a left iron core, an intermediate iron core and a right iron core, the intermediate iron core At least one of the left side core and the right side iron core is wound around the first winding. The edge-wound winding transformer according to claim 3, wherein the left iron core and the right iron core are respectively wound around the second winding, and are disposed around the left iron core and the right iron core. The second windings are connected in series to each other. The edge-wound winding transformer according to claim 3, wherein the left iron core and the right iron core are respectively wound around the second winding, and are disposed around the left iron core and the right iron core. The second windings are connected in parallel with each other. The edge-wound winding transformer according to claim 3, wherein the left iron core and the right iron core are respectively wound around the second winding, and the intermediate iron core is provided with the first inner layer a winding and a second winding on the outer layer, in the inner layer An insulating layer is disposed between the first winding and the second winding of the outer layer. A side winding type winding transformer according to claim 6, wherein the second winding wound around the left side core, the right side core, and the intermediate core are connected in series to each other. The edge-wound winding transformer of claim 6, wherein the second winding wound around the left iron core and the right iron core are connected in parallel with each other and then wound around the intermediate iron core. The second winding is connected in series. The side winding type winding transformer according to claim 1, wherein the iron cores are any one of an E type, an I type, a T type, and a U type iron core. The edge-wound winding transformer according to claim 1, wherein the insulating layer may be an insulating tape or an insulating member made of other insulating materials. The side winding type winding transformer according to claim 1, wherein the first winding or the second winding system may be any one of copper wire, copper foil and enameled wire.