TWM615962U - Transformer - Google Patents

Abstract

A transformer includes a drum core and a set of coil wound on the drum core. The set of coil includes a conducting member and an insulating layer covering the conducting member. The conducting member has a diameter ranging from 0.07 mm to 0.2 mm. The insulating layer has an outer diameter. The ratio of the outer diameter of the insulating layer to the diameter of the conducting member ranges from 1.35 to 2.5.

Description

transformer

This disclosure is about a transformer.

PoE (Power over Ethernet) is a technology that supplies power through a network cable. The network cable can be used to realize the transmission of data and power, so that the device does not need to be connected to other external power sources. With the advancement of technology, the demand for bandwidth is increasing. However, the current design of PoE network transformers has poor impedance characteristics at high frequencies, and it is difficult to meet the requirements of high-bandwidth transmission (for example: 10GBASE-T).

In view of this, one purpose of the present disclosure is to provide a PoE network transformer that can achieve high frequency bandwidth and low loss.

To achieve the above objective, according to some embodiments of the present disclosure, a transformer includes a first iron core, a primary side coil group, and a secondary side coil group. The first iron core includes a center column, a first flange and a second flange, and the center column is connected between the first flange and the second flange. The primary side coil group is wound on the center column, and both ends of the primary side coil group are connected to the first flange. The secondary side coil group is wound on the center column, and the two ends of the secondary side coil group are connected with the first flange or the second flange. Both ends of the primary side coil group are connected to a first power source, and both ends of the secondary side coil group are connected to a second power source. The first power source is different from the second power source.

According to some embodiments of the present disclosure, a transformer includes a first iron core, a primary side coil group, and a secondary side coil group. The first iron core includes a center column, a first flange and a second flange, and the center column is connected between the first flange and the second flange. The primary side coil group is wound on the center column, and the two ends of the primary side coil group are connected to the first flange, and the middle end of the primary side coil group is connected to the second flange. The secondary side coil group is wound on the center column, and the two ends of the secondary side coil group are connected with the first flange or the second flange. Both ends of the primary side coil group are connected to a first power source, and both ends of the secondary side coil group are connected to a second power source. The first power source is different from the second power source.

In one or more embodiments of the present disclosure, the first power source is an AC power source or a DC power source, and the second power source is a DC power source.

In one or more embodiments of the present disclosure, the primary side coil group includes a first coil and a second coil, one end of the first coil and the second coil is connected to the first flange, and the first coil and the second coil are The other end is connected to the second flange.

In one or more embodiments of the present disclosure, the other ends of the first coil and the second coil are connected to the same conductive pad of the second flange.

In one or more embodiments of the present disclosure, the other ends of the first coil and the second coil are connected to the different conductive pads of the second flange.

In one or more embodiments of the present disclosure, the secondary side coil group includes a third coil and a fourth coil, one end of the third coil and the fourth coil is connected to the first flange, and the third coil and the fourth coil The other end is connected to the second flange.

In one or more embodiments of the present disclosure, the transformer further includes a second iron core, and the second iron core is connected to the first flange and the second flange.

In one or more embodiments of the present disclosure, the primary side coil group or the secondary side coil group has a conductor and an insulating layer covering the conductor.

In one or more embodiments of the present disclosure, the diameter of the conductor falls within the range of 0.07 mm to 0.2 mm, and the ratio of the outer diameter of the insulating layer to the diameter of the conductor falls within the range of 1.35 to 2.5.

In one or more embodiments of the present disclosure, the number of turns of the primary side coil group or the secondary side coil group is 7 to 14.

In one or more embodiments of the present disclosure, the insulating layer is made of polyurethane material, polyester imide material or polyamide composite material.

According to some embodiments of the present disclosure, a transformer includes a drum core and a coil assembly. The coil assembly is wound on the drum core and includes a conductor and an insulating layer covering the conductor. The diameter of the conductor falls within the range of 0.07 mm to 0.2 mm, and the ratio of the outer diameter of the insulating layer to the diameter of the conductor falls within the range of 1.35 to 2.5.

In one or more embodiments of the present disclosure, the coil group is a secondary side coil or a primary side coil.

In one or more embodiments of the present disclosure, the number of turns of the coil group is 7-14.

In summary, in the transformer of this case, at least one of the primary side coil set and the secondary side coil set is configured such that the diameter of the conductor falls within the range of 0.07 mm to 0.2 mm, and the outer diameter of the insulating layer is consistent with that of the conductor. The ratio of diameters falls within the range of 1.35 to 2.5. The above configuration can improve the impedance characteristics under high frequency, so that the transformer in this case can be applied to high frequency bandwidth transmission (for example: 10GBASE-T).

In order to make the description of this disclosure more detailed and complete, reference may be made to the attached drawings and various embodiments described below. The elements in the drawings are not drawn to scale, and are provided only to illustrate the present disclosure. Many practical details are described below to provide a comprehensive understanding of this disclosure. However, those of ordinary skill in the relevant fields should understand that this disclosure can be implemented without one or more practical details. Therefore, these details are not Application to limit this disclosure.

Please refer to Figures 1 and 2, the transformer 100 is, for example, a PoE network transformer, which can be integrated in an RJ-45 connector or installed on a circuit board of the system. The transformer 100 includes a first iron core 110 and a coil group 120 wound around the first iron core 110. The first iron core 110 is, for example, a drum core. The first iron core 110 is made of magnetic material and includes a first flange 111 (flange, or flange), a second flange 112, and a flange connected between the first flange 111 and the second flange 112. In the pillar 119. The coil group 120 includes a primary side coil group 121 and a secondary side coil group 122. The primary side coil group 121 is wound around the central column 119, and both ends of the primary side coil group 121 are connected to the first flange 111. The primary side coil group 121 is The end is connected to the second flange 112. The secondary side coil group 122 is wound around the center column 119, and both ends of the secondary side coil group 122 are connected to the first flange 111.

As shown in Figures 1 and 2, in some embodiments, the primary side coil assembly 121 includes a first coil 121A and a second coil 121B, and the first end 121L of the first coil 121A and the second coil 121B is connected to the first coil 121A and the second coil 121B. A flange 111, and the second ends 121R (relative to the first end 121L) of the first coil 121A and the second coil 121B are connected to the second flange 112. In the above embodiment, the first ends 121L of the first coil 121A and the second coil 121B are connected to both ends of the first flange 111 as the primary side coil group 121, and the second ends of the first coil 121A and the second coil 121B 121R is connected to the middle end of the second flange 112 as the primary side coil group 121. In addition, the first coil 121A and the second coil 121B can be composed of a wire as needed. At this time, a part of the middle section of the aforementioned wire is connected to the second flange 112 as the middle end of the primary side coil assembly 121.

As shown in Figures 1 and 2, in some embodiments, the secondary coil group 122 includes a third coil 122A and a fourth coil 122B, and the first end 122L of the third coil 122A and the fourth coil 122B is connected to The first flange 111 and the second end 122R (relative to the first end 122L) of the third coil 122A and the fourth coil 122B are connected to the second flange 112. In the above embodiment, the first ends 122L of the third coil 122A and the fourth coil 122B are connected to both ends of the first flange 111 as the secondary side coil group 122.

In some embodiments, the primary side coil assembly 121 and the secondary side coil assembly 122 are wound around the center pillar 119 of the first core 110 in a double-wire parallel or twisted manner, and form a double-layer structure covering the center pillar 119. In some embodiments, the primary side coil assembly 121 and the secondary side coil assembly 122 are wound around the center pillar 119 of the first core 110 in a four-wire parallel or twisted manner, and form a single-layer structure covering the center pillar 119.

As shown in Figures 1 and 2, in some embodiments, the transformer 100 further includes a second iron core 130. The second iron core 130 includes a magnetic material and is connected to the first flange 111 of the first iron core 110 and The second flange 112 forms a closed magnetic circuit with the first iron core 110. In some embodiments, two ends of the second core 130 are respectively fixed to the top surface 111A of the first flange 111 and the top surface 112A of the second flange 112. The shape of the second iron core 130 is, for example, a straight shape, a plate shape, or the like.

The transformer 100 combines the structural design of the first iron core 110 and the second iron core 130 to make it suitable for an automated manufacturing process, which can save production time and cost. At the same time, the coil assembly 120 can also be combined with the first iron core 110 by automatic winding, so that the characteristics and quality of the transformer 100 can be easily controlled.

As shown in FIGS. 1 and 2, in some embodiments, the transformer 100 further includes a plurality of conductive pads 140, and the conductive pads 140 are disposed on the first iron core 110 and used to connect the coil assembly 120.

As shown in FIGS. 1 and 2, specifically, the conductive pad 140 includes four first conductive pads 141A, 141B, 141C, and 141D, and the first conductive pads 141A, 141B, 141C, and 141D are separately disposed on the first A flange 111 is far away from the top surface 111A and arranged along the direction X, which is substantially perpendicular to the direction Y in which the central pillar 119 of the first iron core 110 extends. The first conductive pads 141A and 141B form a pair and are respectively connected to the first ends 121L of the first coil 121A and the second coil 121B. The first conductive pads 141C and 141D form a pair and are respectively connected to the first ends 122L of the third coil 122A and the fourth coil 122B.

As shown in Figures 1 and 2, in some embodiments, the two pairs of first conductive pads are separated by a gap G1. In the direction X, the width of the gap G1 is greater than the distance between any pair of first conductive pads ( For example: the distance between the first conductive pads 141A and 141B, or the distance between the first conductive pads 141C and 141D). In some embodiments, the first flange 111 has a plurality of protrusions A1 on the side away from the top surface 111A, and the first conductive pads 141A, 141B, 141C, and 141D are disposed on the protrusions A1 of the first flange 111 .

As shown in Figures 1 and 2, the conductive pad 140 further includes four second conductive pads 142A, 142B, 142C, 142D, and the second conductive pads 142A, 142B, 142C, 142D are separately arranged on the second flange 112 is away from the side of the top surface 112A, and is arranged along the direction X. The second conductive pads 142A and 142B form a pair and are respectively connected to the second end 121R of the second coil 121B and the first coil 121A. In other words, the second end 121R of the first coil 121A and the second coil 121B is connected to the second method Lan 112 is a different conductive pad. The second conductive pads 142C and 142D form a pair and are respectively connected to the second ends 122R of the fourth coil 122B and the third coil 122A.

As shown in Figures 1 and 2, in some embodiments, the two pairs of second conductive pads are separated by a gap G2. In the direction X, the width of the gap G2 is greater than the distance between any pair of second conductive pads ( For example: the distance between the second conductive pads 142A and 142B, or the distance between the second conductive pads 142C and 142D). In some embodiments, the second flange 112 has a plurality of protrusions A2 on the side away from the top surface 112A, and the second conductive pads 142A, 142B, 142C, 142D are disposed on the protrusions A2 of the second flange 112 .

As shown in Figures 1 and 2, both ends of the primary side coil group 121 are connected to the first power source P1 at the first flange 111, and both ends of the secondary side coil group 122 are connected to the first flange 111 and the second power source. P2 is connected, and the first power source P1 is different from the second power source P2. In some embodiments, the first power source P1 is an AC power source or a DC power source, and the second power source P2 is a DC power source.

Referring to FIG. 3, the coil assembly 120 includes a conductor C and an insulating layer I. The insulating layer I covers the conductor C, that is, the insulating layer I covers the outer surface of the conductor C. In some embodiments, the conductor C includes copper or other suitable conductive materials, and the insulating layer I includes a polyurethane material, a polyester imide material, a polyamide composite material, other suitable insulating materials, or any combination of the foregoing materials.

As shown in FIG. 3, the cross-section of the conductor C of the coil assembly 120 is substantially disk-shaped and has a diameter D1, which falls within a range of 0.07 mm to 0.2 mm. The insulating layer I of the coil group 120 has an outer diameter D2. Specifically, the insulating layer I has opposite inner and outer surfaces, wherein the inner surface is in contact with the conductor C, and the outer diameter D2 of the insulating layer I refers to the diameter of the outer surface of the insulating layer 1. The ratio of the outer diameter D2 of the insulating layer I to the diameter D1 of the conductor C falls within the range of 1.35 to 2.5.

When the coil assembly 120 is designed to have the above-mentioned size, the impedance characteristic of the transformer 100 at high frequencies can be improved, and therefore it can be applied to high-bandwidth transmission (for example: 10GBASE-T). Specifically, the transformer 100 of the present application is appropriately configured with the size of the conductor C and the insulating layer I, thereby changing the distributed capacitance between the conductors, thereby improving the impedance characteristics at high frequencies.

In some embodiments, the secondary side coil set 122 has the above-mentioned size, that is, the diameter D1 of the conductor C of the third coil 122A and the fourth coil 122B falls within the range of 0.07 mm to 0.2 mm, and the third coil 122A And the ratio of the outer diameter D2 of the insulating layer I of the fourth coil 122B to the diameter D1 of the conductor C falls within the range of 1.35 to 2.5. In some embodiments, the primary side coil set 121 has the above-mentioned size, that is, the diameter D1 of the conductor C of the first coil 121A and the second coil 121B falls within the range of 0.07 mm to 0.2 mm, and the first coil 121A and The ratio of the outer diameter D2 of the insulating layer I of the second coil 121B to the diameter D1 of the conductor C falls within the range of 1.35 to 2.5. In some embodiments, both the secondary side coil group 122 and the primary side coil group 121 have the above-mentioned dimensions.

In some embodiments, the number of turns of the coil set 120 is 7 to 14 to obtain better impedance characteristics. Specifically, the aforementioned number of turns refers to the number of turns that the coil assembly 120 extends from the first flange 111 to the second flange 112 and is wound on the center pillar 119. In some embodiments, the number of turns of the secondary side coil group 122 or the primary side coil group 121 is 7-14, or the number of turns of the secondary side coil group 122 and the primary side coil group 121 are both 7-14.

Please refer to Figure 4, which shows the relationship between the loss L and the bandwidth B at different diameter ratios R when the diameter D1 of the conductor C of the coil assembly 120 is fixed at 0.1 mm and the material of the insulating layer I is polyurethane. In the curve, the diameter ratio R refers to the ratio of the outer diameter D2 of the insulating layer I of the coil assembly 120 to the diameter D1 of the conductor C, the unit of loss L is dB, and the unit of bandwidth B is MHz.

The fourth icon shows the first bandwidth design range B1, the second bandwidth design range B2, and the third bandwidth design range B3. The first bandwidth design range B1 is applicable to specifications below 1G/2.5GBASE-T. The second bandwidth design range B2 is suitable for 5GBASE-T specifications, and the third bandwidth design range B3 is suitable for 10GBASE-T specifications.

As shown in Figure 4, when the diameter ratio R falls within the range of 1.35 to 2.5, the loss can be effectively controlled above the target value -1 in the third bandwidth design range B3. Therefore, when the coil group 120 is configured to have a diameter ratio R of 1.35 to 2.5, it can be applied to high-bandwidth transmission of 10GBASE-T. In addition, when the coil group 120 is configured to have a diameter ratio R of 1.35 to 2.5, the loss can also be effectively controlled above the target value -1 in the first bandwidth design range B1 and the second bandwidth design range B2. Therefore, Compatible with specifications below 5GBASE-T or 1G/2.5GBASE-T. Conversely, when the diameter ratio R is lower than 1.35 or exceeds 2.5 (for example, 1.2 or 2.6), the loss in the high-frequency region drops below -1, which is not suitable for 10GBASE-T high-bandwidth transmission.

Please refer to FIG. 5, which is a graph showing the relationship between loss and bandwidth under different conductor diameters D1 when the diameter ratio R of the coil assembly 120 is fixed at 1.35 and the material of the insulating layer I is polyurethane. When the diameter D1 of the conductor C falls within the range of 0.07 mm to 0.2 mm, the loss can be effectively controlled above the target value -1 in the third bandwidth design range B3. Therefore, it can be applied to the high-bandwidth transmission of 10GBASE-T , And compatible with the specifications below 5GBASE-T or 1G/2.5GBASE-T. Conversely, when the diameter D1 of the conductor C is less than 0.07 mm or greater than 0.2 mm (for example, 0.21 mm), the loss in the high-frequency region drops below -1, which is not suitable for the high-bandwidth transmission of 10GBASE-T.

Referring to FIG. 6, compared with the foregoing embodiment, the second flange 112 of the first iron core 110 of the transformer 200 of this embodiment is provided with a single second conductive pad 242E instead of the second conductive pads 142A, 142B, and the primary side The second ends 121R of the first coil 121A and the second coil 121B of the coil assembly 121 are both connected to the second conductive pad 242E. In other words, the second ends 121R of the first coil 121A and the second coil 121B are connected to the second flange The same conductive pad 112 is electrically connected directly through the second conductive pad 242E.

Referring to Figure 7, the difference between this embodiment and the previous embodiment is that the two ends of the secondary side coil assembly 122 are connected to the second flange 112, and the two ends of the secondary side coil assembly 122 are connected between the second flange 112 and the second flange 112. The power source P2 is connected so that the first power source P1 and the second power source P2 are connected to different flanges of the first iron core 110 of the transformer 300. In some embodiments, the second power source P2 is electrically connected to the secondary side coil assembly 122 through the second conductive pads 142D and 142C. In some embodiments, the first ends 122L of the third coil 122A and the fourth coil 122B of the secondary side coil group 122 are connected to the second flange 112, and the second ends 122R of the third coil 122A and the fourth coil 122B Connected to the first flange 111. The first ends 122L of the third coil 122A and the fourth coil 122B are connected to the two ends of the second flange 112 as the secondary side coil group 122 and connected to the second power source P2.

In summary, in the transformer of this case, at least one of the primary side coil set and the secondary side coil set is configured such that the diameter of the conductor falls within the range of 0.07 mm to 0.2 mm, and the outer diameter of the insulating layer is consistent with that of the conductor. The ratio of diameters falls within the range of 1.35 to 2.5. The above configuration can improve the impedance characteristics under high frequency, so that the transformer in this case can be applied to high frequency bandwidth transmission (for example: 10GBASE-T).

Although the present disclosure has been disclosed in the above manner, it is not intended to limit the present disclosure. Anyone who is familiar with this technique can make various changes and modifications without departing from the spirit and scope of the present disclosure. Therefore, the protection of this disclosure The scope shall be subject to the definition of the attached patent application scope.

100, 200, 300: Transformer 110: The first core 111: first flange 111A, 112A: top surface 112: second flange 119: Center Column 120: coil group 121: Primary side coil group 121A: first coil 121B: second coil 121L, 122L: first end 121R, 122R: second end 122: Secondary side coil group 122A: third coil 122B: fourth coil 130: second core 140: Conductive pad 141A, 141B, 141C, 141D: first conductive pad 142A, 142B, 142C, 142D, 242E: second conductive pad A1, A2: convex part B: Bandwidth B1, B2, B3: bandwidth design range C: Conductor D1: diameter D2: Outer diameter G1, G2: gap I: Insulation layer L: loss P1: First power supply P2: second power supply R: Diameter ratio X, Y: direction

In order to make the above and other objectives, features, advantages and implementations of the present disclosure more obvious and understandable, the description of the accompanying drawings is as follows: FIG. 1 is a three-dimensional schematic diagram of a transformer according to an embodiment of the present disclosure. Figure 2 is a schematic bottom view of the transformer shown in Figure 1. FIG. 3 is a schematic cross-sectional view showing the coil assembly of the transformer shown in FIG. 1. FIG. Figure 4 is a graph showing the relationship between loss and bandwidth at different diameter ratios when the conductor diameter of the coil assembly is fixed at 0.1 mm and the insulating layer is made of polyurethane. The diameter ratio refers to the coil assembly’s The ratio of the outer diameter of the insulating layer to the diameter of the conductor. Figure 5 is a graph showing the relationship between the loss and the bandwidth of different conductor diameters when the diameter ratio of the coil assembly is fixed at 1.35 and the material of the insulating layer is polyurethane. FIG. 6 is a schematic bottom view of a transformer according to another embodiment of the present disclosure. FIG. 7 is a schematic bottom view of a transformer according to another embodiment of the present disclosure.

100: Transformer

110: The first core

111: first flange

111A, 112A: top surface

112: second flange

119: Center Column

120: coil group

130: second core

140: Conductive pad

141A, 141B, 141C, 141D: first conductive pad

142A, 142B: second conductive pad

A1, A2: convex part

G1: gap

Claims (20)

A transformer including: A first iron core including a center column, a first flange and a second flange, the center column is connected between the first flange and the second flange; A primary side coil set wound around the center column, and both ends of the primary side coil set are connected to the first flange; and The secondary side coil group is wound on the center column, and both ends of the secondary side coil group are connected to the first flange or the second flange; The two ends of the primary side coil group are connected to a first power source, and the two ends of the secondary side coil group are connected to a second power source, wherein the first power source is different from the second power source. The transformer according to claim 1, wherein the first power source is an AC power source or a DC power source, and the second power source is a DC power source. The transformer according to claim 1, wherein the primary side coil set includes a first coil and a second coil, one end of the first coil and the second coil is connected to the first flange, and the first coil And the other end of the second coil is connected to the second flange. The transformer according to claim 1, wherein the secondary side coil group includes a third coil and a fourth coil, one end of the third coil and the fourth coil is connected to the first flange, and the third coil The other end of the coil and the fourth coil is connected to the second flange. The transformer according to claim 1, further comprising a second iron core, and the second iron core is connected to the first flange and the second flange. A transformer including: A first iron core including a center column, a first flange and a second flange, the center column is connected between the first flange and the second flange; A primary side coil group wound around the center column, two ends of the primary side coil group are connected to the first flange, and the middle end of the primary side coil group is connected to the second flange; and The secondary side coil group is wound on the center column, and both ends of the secondary side coil group are connected to the first flange or the second flange; The two ends of the primary side coil group are connected to a first power source, and the two ends of the secondary side coil group are connected to a second power source, wherein the first power source is different from the second power source. The transformer according to claim 6, wherein the first power source is an AC power source or a DC power source, and the second power source is a DC power source. The transformer according to claim 6, wherein the primary side coil group includes a first coil and a second coil, one end of the first coil and the second coil is connected to the first flange, and the first coil And the other end of the second coil is connected to the second flange. The transformer according to claim 8, wherein the other ends of the first coil and the second coil are connected to the same conductive pad of the second flange. The transformer according to claim 8, wherein the other ends of the first coil and the second coil are connected to different conductive pads of the second flange. The transformer according to claim 6, wherein the secondary side coil set includes a third coil and a fourth coil, one end of the third coil and the fourth coil is connected to the first flange, and the third coil The other end of the coil and the fourth coil is connected to the second flange. The transformer according to claim 6, further comprising a second iron core, and the second iron core is connected to the first flange and the second flange. The transformer according to claim 6, wherein the primary side coil group or the secondary side coil group has a conductor and an insulating layer, and the insulating layer covers the conductor. The transformer according to claim 13, wherein the diameter of the conductor falls within the range of 0.07 mm to 0.2 mm, and the ratio of the outer diameter of the insulating layer to the diameter of the conductor falls within the range of 1.35 to 2.5. The transformer according to claim 13, wherein the number of turns of the primary side coil group or the secondary side coil group is 7 to 14. The transformer according to claim 13, wherein the insulating layer is made of polyurethane material, polyester imide material or polyamide composite material. A transformer including: A drum core; and A coil set wound on the drum-shaped iron core and including a conductor and an insulating layer, the insulating layer covering the conductor; The diameter of the conductor falls within the range of 0.07 mm to 0.2 mm, and the ratio of the outer diameter of the insulating layer to the diameter of the conductor falls within the range of 1.35 to 2.5. The transformer according to claim 17, wherein the coil group is a secondary side coil or a primary side coil. The transformer according to claim 17, wherein the number of turns of the coil group is 7 to 14. The transformer according to claim 17, wherein the insulating layer is made of polyurethane material, polyester imide material or polyamide composite material.

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