WO2019091353A1 - 一种平板变压器及开关电源适配器 - Google Patents

一种平板变压器及开关电源适配器 Download PDF

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Publication number
WO2019091353A1
WO2019091353A1 PCT/CN2018/113988 CN2018113988W WO2019091353A1 WO 2019091353 A1 WO2019091353 A1 WO 2019091353A1 CN 2018113988 W CN2018113988 W CN 2018113988W WO 2019091353 A1 WO2019091353 A1 WO 2019091353A1
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Prior art keywords
winding
magnetic core
pcb
primary
panel transformer
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PCT/CN2018/113988
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English (en)
French (fr)
Inventor
胡艳军
苗尊庆
王春富
赵为阳
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华为技术有限公司
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Application filed by 华为技术有限公司 filed Critical 华为技术有限公司
Priority to EP21206837.3A priority Critical patent/EP4006928B1/en
Priority to EP18875827.0A priority patent/EP3693982B1/en
Publication of WO2019091353A1 publication Critical patent/WO2019091353A1/zh
Priority to US16/867,775 priority patent/US11551848B2/en

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/02Casings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2804Printed windings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • H01F27/245Magnetic cores made from sheets, e.g. grain-oriented
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2866Combination of wires and sheets
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/29Terminals; Tapping arrangements for signal inductances
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/30Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306Fastening or mounting coils or windings on core, casing or other support
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/32Insulating of coils, windings, or parts thereof
    • H01F27/324Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00Cores, Yokes, or armatures
    • H01F3/10Composite arrangements of magnetic circuits
    • H01F3/14Constrictions; Gaps, e.g. air-gaps
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/0296Conductive pattern lay-out details not covered by sub groups H05K1/02 - H05K1/0295
    • H05K1/0298Multilayer circuits
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/30Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
    • H05K3/328Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by welding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00Fixed inductances of the signal type 
    • H01F17/04Fixed inductances of the signal type  with magnetic core
    • H01F2017/048Fixed inductances of the signal type  with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/06Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
    • H01F2027/065Mounting on printed circuit boards
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2804Printed windings
    • H01F2027/2809Printed windings on stacked layers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2804Printed windings
    • H01F2027/2819Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion

Definitions

  • the invention relates to the technical field of transformers, in particular to a flat panel transformer and a switching power supply adapter using the same.
  • the switching power adapter is a rechargeable battery that is supplied to a terminal (for example, a mobile phone, a tablet, a camera, etc.) after converting the alternating current into a low-voltage direct current to charge the rechargeable battery.
  • a terminal for example, a mobile phone, a tablet, a camera, etc.
  • a flat-panel transformer (or planar transformer) is a type of transformer that is the core device for power conversion.
  • the flat-panel transformer uses a small-sized E-type, RM-type or ring-type ferrite core, usually made of high-frequency power ferrite material, with low core loss at high frequencies;
  • the circuit board is wound and formed, and the winding or the copper piece is stacked on the flat high-frequency iron core to form a magnetic circuit of the transformer.
  • the flat panel transformer has the advantages of low electromagnetic interference (EMI) radiation and small volume.
  • EMI electromagnetic interference
  • the flat-panel transformer used in the current switching power adapter is a horizontal structure as shown in FIG. 1.
  • the flat-panel transformer in FIG. 1 includes a magnetic core 1, a printed circuit board (PCB) board 2, and a soldering The PIN pin 3 at the PCB; where the PCB board is the winding of the transformer. Connect to the power strip in the switching power adapter via PIN pin 3.
  • the process of soldering a PIN pin on a PCB is very complicated and the processing cost is high.
  • such a horizontally structured flat panel transformer occupies a large area on the power board, resulting in low space utilization in the switching power supply adapter.
  • the present application provides a flat-panel transformer and a switching power adapter to solve the technical problem of complicated processing and high cost of the current flat-panel transformer.
  • the present application provides a flat panel transformer comprising: a printed circuit board PCB winding, an insulating cover, a first magnetic core and a second magnetic core.
  • the PCB winding comprises a winding body, a primary side winding and a secondary side winding
  • the winding body comprises a primary winding and a secondary winding
  • the primary side trace is a lead line of the primary side winding
  • the secondary side trace is a secondary side a lead wire of the winding, and a predetermined insulation distance between the primary winding and the secondary side trace.
  • the end of the primary side trace is provided with a first set of solder joints in electrical communication with the primary side winding
  • the end of the secondary side trace is provided with a second set of solder joints in electrical communication with the secondary winding, the first set of solder joints and The second set of solder joints is connected to an external circuit.
  • the first core and the second core are respectively wrapped on both sides of the winding body to form a closed magnetic circuit.
  • the insulating cover is wrapped on the outer side of the first magnetic core, the second magnetic core, and the secondary side trace.
  • a first set of solder joints is disposed at an end of the primary side trace
  • a second set of solder joints is disposed at an end of the secondary side trace
  • the flat plate is passed through the first set of solder joints and the second set of solder joints
  • the transformer is soldered to the circuit board, so that the PIN pin is not required to be soldered on the PCB winding board. Therefore, the processing procedure of the flat-panel transformer is simplified, the fully automated processing can be realized, the processing time cost is reduced, and the processing efficiency is improved.
  • the flat panel transformer can be vertically mounted on the external circuit board through the first set of solder joints and the second set of solder joints.
  • the vertical mounting method reduces the space required to occupy the external circuit board and improves The space utilization of the board.
  • the arrangement of the insulating cover can increase the insulation distance between the primary side and the low voltage component outside the panel transformer, thereby improving the safety performance of the flat panel transformer.
  • a U-shaped groove is disposed between the winding body and the secondary side wire to increase the relationship between the first magnetic core, the second magnetic core, and the primary winding and the secondary winding Insulation distance. Thereby improving the safety performance of the flat panel transformer.
  • the insulating cover is provided with an insulating sheet, the thickness of the insulating sheet is matched with the groove width of the U-shaped groove, and when the insulating cover is assembled, the insulating sheet is U-shaped. In the slot, thereby increasing the electrical gap between the primary winding and the secondary winding, further improving the safety performance of the flat transformer.
  • the plane of the winding body is provided with a through hole, and the first magnetic core and the second magnetic core are disposed on a side of the winding body with a convex shape matching the through hole. a stage, the first core and the second core are aligned with a predetermined air gap to prevent saturation of the flat transformer; the first core and the second core are provided with two sides on one side of the PCB winding The post, the first core and the second core are in closed contact by the side legs.
  • the length of the side of the primary side and the secondary side of the trace is longer than the length of the body of the PCB winding. That is, both ends of the PCB winding have a convex shape, which can protect the core from impact cracking.
  • the first magnetic core or the second magnetic core and the PCB winding are fixedly connected by an adhesive; the side pillar of the second magnetic core and the side pillar of the first magnetic core
  • the connection is fixed by adhesive glue.
  • the bonding process is fixed by the adhesive, and the processing process is simple and the efficiency is high.
  • the first core is electrically connected to the ground point of the PCB winding by a conductive paste.
  • the conductive glue is used for fixed connection, and the processing process is simple and efficient.
  • the PCB winding is a single-layer multi-layer PCB board, and an insulating medium is disposed between any two layers of the single-layer PCB board, and any one of the PCBs is a primary winding. Or secondary winding.
  • the present application further provides a switching power adapter, including a power board and a flat transformer according to any one of the possible implementations of the first aspect; the first set of solder joints and the second set of solder joints of the flat transformer are directly Soldered on the power board, and the plane with the largest area of the flat panel transformer is mounted perpendicular to the power board.
  • the contact surface of the flat-panel transformer with the power board is much smaller than the plane with the largest area of the flat-panel transformer.
  • the flat panel transformer provided by the present application comprises a PCB winding and two magnetic cores; wherein two magnetic cores are respectively wrapped on both sides of the winding body of the PCB winding to form a closed magnetic circuit.
  • a first set of soldering points is disposed on the side of the primary side of the PCB winding, and a second set of soldering points is disposed on the side of the side of the secondary side.
  • the planar transformer is soldered directly to the external circuit board through the first set of solder joints and the second set of solder joints. This eliminates the need to solder the PIN pin on the PCB winding board, thus simplifying the processing of the flat-panel transformer and achieving fully automated processing, reducing processing time costs and improving processing efficiency.
  • the flat panel transformer can be vertically mounted on the external circuit board through the first set of solder joints and the second set of solder joints.
  • the vertical mounting method reduces the space required to occupy the external circuit board and improves The space utilization of the external board.
  • FIG. 1 is a schematic structural view of a conventional flat panel transformer
  • FIG. 2 is an exploded view of a flat panel transformer according to an embodiment of the present application.
  • FIG. 3 is a longitudinal cross-sectional view of a flat panel transformer according to an embodiment of the present application.
  • FIG. 4 is a schematic view showing an assembly effect of a flat panel transformer according to an embodiment of the present application.
  • FIG. 5 is a schematic view showing another assembly effect of the panel transformer of the embodiment of the present application.
  • the present application provides a flat panel transformer, which is provided with a first set of soldering points directly on the primary side of the PCB winding, and a second set of soldering points on the secondary side of the winding. Directly soldered directly to the power board in the switching power adapter through the first set of solder joints and the second set of solder joints, eliminating the need to solder the PIN pin on the PCB winding, simplifying the processing of the flat panel transformer and achieving fully automated processing. Reduce processing time costs and increase processing efficiency.
  • the flat-panel transformer when used in the switching power adapter, the flat-panel transformer can be vertically installed on the power board in the switching power adapter through the first set of solder joints and the second set of solder joints, that is, the plane with the largest area of the flat-panel transformer
  • the power board is vertical.
  • the contact surface of the flat-panel transformer with the power board is much smaller than the plane with the largest area. Therefore, the flat-panel transformer can adopt the vertical installation method to reduce the space of the occupied power board and improve the space utilization of the power board.
  • FIG. 2 is a schematic exploded view of a flat-panel transformer according to an embodiment of the present application
  • FIG. 3 is a schematic longitudinal cross-sectional view of a flat-panel transformer according to an embodiment of the present application
  • FIG. 5 is a schematic view showing another assembly effect of the flat-panel transformer of the embodiment of the present application.
  • the flat panel transformer includes a PCB winding 110, a first magnetic core 120, a second magnetic core 130, and an insulating cover 140.
  • the first magnetic core 120 and the second magnetic core 130 are coated on both sides of the PCB winding 110 to form a closed magnetic circuit.
  • the middle portion of the PCB winding 110 is a winding body 111, and a through hole 1110 is disposed in the middle of the winding body;
  • the two sides of the winding body 111 are the primary side trace 112 and the secondary side trace 113 respectively; the winding body 111 includes a primary winding and a secondary winding, the primary side trace is the lead line of the primary winding; the secondary side trace is the secondary The lead wire of the side winding.
  • the outer side of the first magnetic core 120 is a flat surface, and two side pillars 121 are disposed toward the inner side of the PCB winding 110. Moreover, the inner middle portion of the first magnetic core 120 is provided with a boss 122 having a size and a winding body 111. The through hole sizes on the top match. Similarly, the outer side of the second core 130 is a flat surface, two side pillars are disposed on the inner side, and a boss is disposed in the middle portion.
  • the boss of the first core 120 is inserted into the through hole of the PCB winding 110, and then the boss of the second core 130 is inserted into the through hole from the other side of the PCB winding 110, and first The bosses of the magnetic core 120 and the second core 130 are aligned in the through holes of the PCB winding 110, and there is a certain air gap between the two bosses to prevent the transformer from being saturated; meanwhile, the two sides of the first core 120 The post is in closed contact with the two side legs of the second core 130.
  • the first core 120 and the second core 130 form a closed magnetic path through the closed contact between the side post and the boss.
  • the PCB winding is provided with a U-shaped groove 116 between the winding body 111 and the secondary side wire 113, so that the primary side of the planar transformer (ie, the primary winding and the magnetic core) and the secondary side are routed. There is a certain creepage distance between them.
  • the insulating cover 140 is wrapped around the core and the secondary side traces 113 to ensure insulation between the primary windings and the secondary side components on the external circuit board of the planar transformer. Moreover, an insulating sheet matching the U-shaped groove 116 is disposed in the insulating cover 140. After the insulating cover is assembled, the insulating sheet 141 (shown in FIG. 3) is inserted into the U-shaped groove to satisfy the original of the flat-plate transformer. Reinforced insulation requirements between the side and secondary side traces.
  • the end of the primary side trace 112 is provided with a first set of solder joints 114
  • the end of the secondary side traces 113 is provided with a second set of solder joints 115.
  • the first set of solder joints 114 are used to implement electrical connections between the primary side traces and external circuitry
  • the second set of solder joints 115 are used to effect electrical connections between the secondary side traces and external circuitry.
  • the flat transformer can be soldered directly to the external circuit to be connected (for example, the power board in the switching power adapter) through the first set of solder joints 114 and the second set of solder joints 115, without the need to solder the PIN pin on the PCB.
  • the first set of solder joints and the second set of solder joints may be made of gold finger solder joints, and the gold finger is composed of a total rudder gold-colored conductive contact sheet, because the surface is gold-plated and the conductive contacts are arranged like fingers. It is called a gold finger; the contact piece is coated with a layer of highly conductive material (for example, gold, brass, etc.) on a copper clad plate to achieve electrical connection.
  • gold finger solder joints is composed of a total rudder gold-colored conductive contact sheet, because the surface is gold-plated and the conductive contacts are arranged like fingers. It is called a gold finger; the contact piece is coated with a layer of highly conductive material (for example, gold, brass, etc.) on a copper clad plate to achieve electrical connection.
  • first set of solder joints 114 and the second set of solder joints 115 may each comprise a plurality of solder joints, and the number of solder joints specifically included is related to the specific structure of the windings in the flat panel transformer.
  • the largest side of the PCB winding 110 is H-shaped, that is, both ends of the PCB winding 110 have a convex shape.
  • the height of the side where the primary side trace 112 of the PCB winding 110 is located and the side of the secondary side trace 113 is greater than the height of the intermediate winding body 111; and the height difference between the side of the primary side trace and the secondary side trace is larger than that of the first core And the height of the second core; thus, the two sides of the PCB winding are convex shapes.
  • the PCB winding is a single multi-layer PCB board, and each layer of the PCB board is printed with a winding, and an insulating medium is disposed between any two layers of the PCB board (for example, a prepreg PP, or Core board CORE); both the primary winding and the secondary winding comprise a multilayer PCB board, which is realized by an insulating medium between the PCB layers, between the primary windings, between the secondary windings, and between the primary windings and the secondary windings.
  • the lead wires of the plurality of PCB layers constituting the primary winding are connected in series to obtain the primary winding, and similarly, the plurality of PCB layers constituting the secondary winding are connected in series to obtain the secondary winding. Since the primary winding and the secondary winding are respectively located in different PCB layers, the primary and secondary windings are located on different PCB layers.
  • the flat panel transformer provided in this embodiment includes a PCB winding and two magnetic cores; the two magnetic cores respectively cover the PCB windings to form a closed magnetic circuit.
  • the outer edges of the two magnetic cores and the secondary side traces are covered with an insulating cover, which can meet the reinforced insulation requirements of the flat-panel transformer.
  • a first set of soldering points is disposed on the side of the primary side of the PCB winding, and a second set of soldering points is disposed on the side of the side of the secondary side.
  • the planar transformer is soldered directly to the external circuit board through the first set of solder joints and the second set of solder joints.
  • the flat panel transformer can be vertically mounted on the external circuit board through the first set of solder joints and the second set of solder joints. Compared with the horizontal flat panel transformer, the vertical mounting method reduces the space required to occupy the external circuit board and improves The space utilization of the external board.
  • the grounding end of the PCB winding 110 is fixedly connected to the second magnetic core 130 through the conductive adhesive to realize magnetic core grounding shielding.
  • the effect diagram of assembling the above assembly process is shown in Figure 5.
  • the flat-panel transformer When the flat-panel transformer is applied in the switching power adapter, it is mounted on the power supply board of the switching power adapter according to the direction of the arrow shown in FIG. 5, and the contact plane between the flat-panel transformer and the power board is the bottom surface of the flat-plate transformer shown in FIG. 5.
  • the area is much smaller than the contact area of the horizontal flat-panel transformer and the power board shown in Figure 1 (the largest area of the flat-panel transformer). Therefore, the flat panel transformer greatly improves the space utilization of the power board.
  • the flat-panel transformer provided by the embodiment of the present invention uses the adhesive glue and the conductive adhesive to realize the fixed connection between the magnetic core and the PCB winding, and the soldering point is reserved in the primary side line and the secondary side line respectively, so that the PCB is not required.
  • the PIN pin is welded to the windings, and the assembly process is very simple and easy to automate.
  • the flat-panel transformer can be vertically assembled on the power board directly through two sets of solder joints, thereby improving the space utilization of the power board.
  • the embodiment of the present application further provides a switching power adapter, which includes the flat transformer, the power board and other circuit components provided by any of the above embodiments; wherein the flat transformer passes the first set of solder joints And the second set of soldering points are vertically assembled on the power board, that is, the plane with the largest area of the panel transformer is perpendicular to the plane with the largest area of the power board.
  • the utilization space of the power board is greatly saved, the space utilization rate of the power board is improved, and the volume of the switching power adapter is reduced.

Abstract

本申请提供了一种平板变压器及开关电源适配器,其中,该平板变压器包括PCB绕组和两个磁芯;其中,两个磁芯分别包覆在PCB绕组的绕组本体的两侧,形成闭合磁路。在PCB绕组的原边走线侧设置有第一组焊接点,副边走线侧设置有第二组焊接点。通过第一组焊接点和第二组焊接点将平板变压器直接焊接到外部电路板上。这样不需要在PCB绕组板上焊接PIN针,因此,简化了平板变压器的加工工序,实现了全自动化加工,降低了加工时间成本,提高了加工效率。而且,平板变压器通过第一组焊接点和第二组焊接点能够竖式安装在外部电路板上,与卧式平板变压器相比,竖式安装方式减少了所需占用外部电路板的空间,提高了外部电路板的空间利用率。

Description

一种平板变压器及开关电源适配器
本申请要求于2017年11月09日提交中国专利局、申请号为201711097615.0、发明名称为“一种平板变压器及开关电源适配器”的中国专利申请的优先权,其全部内容通过引用结合在本申请中。
技术领域
本发明涉及变压器技术领域,尤其涉及一种平板变压器及应用该平板变压器的开关电源适配器。
背景技术
开关电源适配器是将交流电转换为低压直流电后提供给终端(例如,手机、平板电脑、相机等)内的可充电电池,实现为可充电电池充电。
平板变压器(或,平面变压器)是变压器的一种,是电源功率转换的核心器件。平板变压器采用小尺寸的E型、RM型或环型铁氧体磁芯,通常是由高频功率铁氧体材料制成,在高频下有较低的磁芯损耗;绕组采用多层印刷电路板迭绕而成,绕组或铜片迭在平面的高频铁芯上构成变压器的磁回路。平板变压器具有低电磁干扰(Electromagnetic Interference,EMI)辐射、体积小等优点。
目前的开关电源适配器中使用的平板变压器都是如图1所示的卧式结构,图1中的平板变压器包括磁芯1、印制电路板(Printed Circuit Board,PCB)板2,以及,焊接在PCB处的PIN针3;其中,PCB板是变压器的绕组。通过PIN针3与开关电源适配器中的电源板连接。在PCB上焊接PIN针的工序非常复杂、加工成本高。而且,这种卧式结构的平板变压器会占据电源板上的大量面积,导致开关电源适配器内的空间利用率低。
发明内容
有鉴于此,本申请提供了一种平板变压器和开关电源适配器,以解决目前的平板变压器的加工工序复杂、成本高的技术问题。
第一方面,本申请提供了一种平板变压器,包括:印制电路板PCB绕组、绝缘罩、第一磁芯和第二磁芯。其中,该PCB绕组包括绕组本体、原边走线和副边走线,该绕组本体包括原边绕组和副边绕组,原边走线是原边绕组的引出线,副边走线是副边绕组的引出线,且所述原边绕组与所述副边走线之间具有预设绝缘距离。原边走线的末端设置有与所述原边绕组电连通的第一组焊接点,副边走线的末端设置有与副边绕组电连通的第二组焊接点,第一组焊接点和第二组焊接点连接外部电路。第一磁芯和第二磁芯分别包覆在绕组本体两侧,形成闭合磁路。绝缘罩包覆在第一磁芯、第二磁芯和副边走线的外侧。
本实施例提供的平板变压器,在原边走线的末端设置第一组焊接点,在副边走线的末端设置第二组焊接点,通过该第一组焊接点和第二组焊接点将平板变压器焊接到电路板上,这样不需要在PCB绕组板上焊接PIN针,因此,简化了平板变压器的加工工序,能够实现全自动化加工,降低了加工时间成本,提高了加工效率。而且,平板变压器通过第一组焊接点和第二组焊接点能够竖式安装在外部电路板上,与卧式平板变压器相比,竖式安装方 式减少了所需占用外部电路板的空间,提高了电路板的空间利用率。此外,绝缘罩的设置能够增加原边侧与平板变压器外部的低压元件之间的绝缘距离,提高了平板变压器的安全性能。
在第一方面一种可能的实现方式中,绕组本体与副边走线之间设置有U型槽,以增加第一磁芯、第二磁芯和原边绕组分别与副边走线之间的绝缘距离。从而提高了平板变压器的安全性能。
在第一方面的另一种可能的实现方式中,绝缘罩内设置有绝缘片,该绝缘片的厚与U型槽的槽宽相匹配,当绝缘罩装配好后,该绝缘片处于U型槽内,从而增加原边绕组与所述副边走线之间的电气间隙,进一步提高了平板变压器的安全性能。
在第一方面的又一种可能的实现方式中,绕组本体所在平面设置有通孔,第一磁芯和第二磁芯朝向该绕组本体的一侧设置有形状与该通孔相匹配的凸台,第一磁芯和第二磁芯的凸台对齐且具有预设气隙,从而防止该平板变压器饱和;第一磁芯和第二磁芯朝向PCB绕组的一侧均设置有两个边柱,第一磁芯和第二磁芯通过边柱闭合接触。
在第一方面的再一种可能的实现方式中,在PCB绕组面积最大的一面上,原边走线和副边走线所在边的长度长于所述PCB绕组本体的长度。即,PCB绕组的两端是凸出形状,这样能够保护磁芯避免撞击碎裂。
在第一方面的另一种可能的实现方式中,第一磁芯或第二磁芯与PCB绕组之间通过粘接胶固定连接;第二磁芯的边柱与第一磁芯的边柱之间通过粘接胶固定连接。通过粘接胶固定连接,加工工艺简单,效率高。
在第一方面的又一种可能的实现方式中,第一磁芯与PCB绕组的接地点之间通过导电胶电连接。利用导电胶固定连接,加工工艺简单且效率高。
在第一方面的再一种可能的实现方式中,PCB绕组是单块多层PCB板,单块多层PCB板中任意两层PCB之间为绝缘介质,且任意一层PCB是原边绕组或副边绕组。
第二方面,本申请还提供一种开关电源适配器,包括电源板和第一方面任意一种可能的实现方式所述的平板变压器;该平板变压器的第一组焊接点和第二组焊接点直接焊接在电源板上,且该平板变压器的面积最大的平面垂直于电源板安装。这样,平板变压器与电源板的接触面远远小于平板变压器面积最大的平面。从而减少了平板变压器所需占用电源板的空间,提高了电源板的空间利用率,进而减小了开关电源适配器的体积。
本申请提供的平板变压器包括PCB绕组和两个磁芯;其中,两个磁芯分别包覆在PCB绕组的绕组本体的两侧,形成闭合磁路。在PCB绕组的原边走线侧设置有第一组焊接点,副边走线侧设置有第二组焊接点。通过第一组焊接点和第二组焊接点将平板变压器直接焊接到外部电路板上。这样不需要在PCB绕组板上焊接PIN针,因此,简化了平板变压器的加工工序,实现了全自动化加工,降低了加工时间成本,提高了加工效率。而且,平板变压器通过第一组焊接点和第二组焊接点能够竖式安装在外部电路板上,与卧式平板变压器相比,竖式安装方式减少了所需占用外部电路板的空间,提高了外部电路板的空间利用率。
附图说明
图1是传统的平板变压器的结构示意图;
图2是本申请实施例一种平板变压器的爆炸图;
图3是本申请实施例一种平板变压器的纵向剖视图;
图4是本申请实施例一种平板变压器的装配效果示意图;
图5是本申请实施例平板变压器的另一种装配效果示意图。
具体实施方式
为了解决上述问题,本申请提供了一种平板变压器,该平板变压器直接在PCB绕组的原边走线上设置有第一组焊接点,以及,在副边走线上设置有第二组焊接点;直接通过第一组焊接点和第二组焊接点直接焊接到开关电源适配器内的电源板上,不需要在PCB绕组上焊接PIN针,简化了平板变压器的加工工序,实现了全自动化加工,降低了加工时间成本,提高了加工效率。而且,当平板变压器应用在开关电源适配器内时,平板变压器通过第一组焊接点和第二组焊接点能够竖式安装在开关电源适配器内的电源板上,即,平板变压器面积最大的平面与电源板垂直。平板变压器与电源板的接触面远远小于该面积最大的平面。因此,该平板变压器能够采用竖式安装方式减少了占用的电源板的空间,提高了电源板的空间利用率。
请参见图2-图5,图2示出了本申请实施例一种平板变压器的爆炸示意图;图3示出了本申请实施例一种平板变压器纵向剖面示意图;图4示出了本申请实施例一种平板变压器装配效果示意图;图5示出了本申请实施例平板变压器的另一种装配效果示意图。
如图2所示,该平板变压器包括PCB绕组110、第一磁芯120、第二磁芯130和绝缘罩140。第一磁芯120和第二磁芯130包覆在PCB绕组110的两侧形成闭合磁路。
PCB绕组110的中间部分是绕组本体111,绕组本体的中间设置有通孔1110;
绕组本体111的两侧分别是原边走线112和副边走线113;绕组本体111包括原边绕组和副边绕组,原边走线即原边绕组的引出线;副边走线即副边绕组的引出线。
第一磁芯120的外侧是平面,朝向PCB绕组110的内侧设置有两个边柱121,而且,第一磁芯120的内侧中间部分设置有凸台122,该凸台的尺寸与绕组本体111上的通孔尺寸相匹配。同理,第二磁芯130的外侧是平面,内侧设置有两个边柱,中间部分设置有凸台。
组装平板变压器时,将第一磁芯120的凸台插入PCB绕组110的通孔中,然后,将第二磁芯130的凸台从PCB绕组110的另一侧插入通孔中,且第一磁芯120和第二磁芯130的凸台在PCB绕组110的通孔内对齐,且两个凸台之间具有一定的气隙以防止变压器饱和;同时,第一磁芯120的两个边柱与第二磁芯130的两个边柱闭合接触。这样,第一磁芯120和第二磁芯130通过边柱和凸台之间的闭合接触形成闭合磁路。
如图2所示,PCB绕组在绕组本体111和副边走线113之间开设有U型槽116,使得平板变压器的原边侧(即,原边绕组和磁芯)与副边走线之间具有一定的爬电距离。
如图4所示,绝缘罩140包覆在磁芯和副边走线113的外部,保证原边绕组与平板变压器外部电路板上的副边元件之间的绝缘。而且,绝缘罩140内设置有与所述U型槽116相匹配的绝缘片,当绝缘罩装配好后,绝缘片141(如图3所示)插入U型槽内,以满足平板变压器的原边侧与副边走线之间的加强绝缘要求。
如图3所示,原边走线112的末端设置有第一组焊接点114,副边走线113的末端设置有第二组焊接点115。第一组焊接点114用于实现原边走线与外部电路之间的电连接,第二组焊接点115用于实现副边走线与外部电路之间的电连接。直接通过第一组焊接点114和第二组焊接点115将平板变压器焊接到需要连接的外部电路(例如,开关电源适配器中的电源板)上即可,不需要在PCB板上焊接PIN针。
在本申请的一个实施例中,第一组焊接点和第二组焊接点可以采用金手指焊接点,金手指是由总舵金黄色导电触片组成,因表面镀金且导电触片排列如手指状,故称为金手指;触片在覆铜板上通过特殊工艺覆上一层高导电材料(例如,金,黄铜等)达到电气连接作用。
此外,第一组焊接点114和第二组焊接点115均可以包含多个焊接点,具体包含的焊接点的数量与平板变压器内绕组的具体结构有关。
在本申请的一个实施例中,如图3所示,PCB绕组110面积最大的一面为H型,即PCB绕组110的两端为凸起形状。PCB绕组110的原边走线112所在边和副边走线113所在边的高度大于中间绕组本体111的高度;而且,原边走线和副边走线所在边的高度差大于第一磁芯和第二磁芯的高度;这样,PCB绕组两边均为凸起形状,当平板变压器的顶部受到撞击时,PCB绕组上凸出的位置承受外壳的冲击,从而避免磁芯受冲击造成磁芯碎落。
在本申请的一个实施例中,PCB绕组是一个单块多层PCB板,每一层PCB板上印制有绕组,任意两层PCB板之间设置有绝缘介质(例如,半固化片PP,或,芯板CORE);原边绕组和副边绕组均包含多层PCB板,通过PCB层间绝缘介质实现、原边绕组之间、副边绕组之间,以及原边绕组和副边绕组之间的绝缘;构成原边绕组的多个PCB层的引出线相互串联得到原边绕组,同理,构成副边绕组的多个PCB层相互串联得到副边绕组。由于原边绕组和副边绕组分别位于不同的PCB层,因此,原边走线和副边走线位于不同的PCB层。
本实施例提供的平板变压器包括PCB绕组和两个磁芯;两个磁芯分别包覆在PCB绕组上形成闭合磁路。两个磁芯和副边走线的外边包覆有绝缘罩,该绝缘罩能够满足平板变压器的加强绝缘要求。在PCB绕组的原边走线侧设置有第一组焊接点,副边走线侧设置有第二组焊接点。通过第一组焊接点和第二组焊接点将平板变压器直接焊接到外部电路板上。这样不需要在PCB绕组板上焊接PIN针,因此,简化了平板变压器的加工工序,实现了全自动化加工,降低了加工时间成本,提高了加工效率。而且,平板变压器通过第一组焊接点和第二组焊接点能够竖式安装在外部电路板上,与卧式平板变压器相比,竖式安装方式减少了所需占用外部电路板的空间,提高了外部电路板的空间利用率。
下面将详细介绍组装本申请实实施例提供的平板变压器的过程:
S1,在PCB绕组110的一面(例如,A面)或第二磁芯130的内侧与绕组本体对应的位置涂覆粘接胶;
S2,将PCB绕组110的A面与第二磁芯130通过粘接胶固定连接;
S3,将PCB绕组110的接地端通过导电胶与第二磁芯130固定连接,实现磁芯接地屏蔽。
S4,通过高温回流炉固化粘接胶和导电胶;
S5,在第二磁芯130的两个边柱上涂抹粘接胶;
S6,将第一磁芯120和第二磁芯130对齐相扣粘接在一起;
S7,挤压两个磁芯,减少两个磁芯间的粘接胶的厚度,以使两个磁芯紧密贴合在一起;
S8,通过高温回流炉固化两个磁芯之间的粘接胶。
S9,安装绝缘罩。
安装上述装配流程装配好的效果图如图5所示。当该平板变压器应用在开关电源适配器内时,按照图5所示的箭头方向安装到开关电源适配器的电源板上,可见该平板变压器与电源板的接触平面是图5所示的平板变压器的底面的面积,该面积远远小于图1所示的卧式平板变压器与电源板的接触面积(平板变压器中面积最大的一面)。因此,该平板变压器大大提高了电源板的空间利用率。
本申请实施例提供的平板变压器利用粘接胶和导电胶实现磁芯和PCB绕组之间的固定连接,而且,在原边走线和副边走线分别预留有焊接点,从而不需要在PCB绕组上焊接PIN针,组装过程非常简单、很容易实现自动化加工。而且,平板变压器能够直接通过两组焊接点竖式装配于电源板上,提高了电源板的空间利用率。
另一方面,本申请实施例还提供了一种开关电源适配器,该开关电源适配器包括上述任一种实施例提供的平板变压器、电源板和其它电路元件;其中,平板变压器通过第一组焊接点和第二组焊接点立式装配于电源板上,即,平板变压器的面积最大的平面垂直于电源板面积最大的平面。这样,大大节省了电源板的利用空间,提高电源板的空间利用率,进而降低了开关电源适配器的体积。
需要说明的是,本说明书中的各个实施例均采用递进的方式描述,每个实施例重点说明的都是与其他实施例的不同之处,各个实施例之间相同相似的部分互相参见即可。对于装置类实施例而言,由于其与方法实施例基本相似,所以描述的比较简单,相关之处参见方法实施例的部分说明即可。

Claims (9)

  1. 一种平板变压器,其特征在于,包括:印制电路板PCB绕组、绝缘罩、第一磁芯和第二磁芯;
    所述PCB绕组包括绕组本体、原边走线和副边走线,所述绕组本体包括原边绕组和副边绕组,所述原边走线是所述原边绕组的引出线,所述副边走线是所述副边绕组的引出线,且所述原边绕组与所述副边走线之间具有预设绝缘距离;
    所述第一磁芯和所述第二磁芯分别包覆在所述绕组本体两侧,形成闭合磁路;
    所述绝缘罩包覆在所述第一磁芯、所述第二磁芯和所述副边走线的外侧;
    在所述原边走线的末端设置有与所述原边绕组电连通的第一组焊接点,以及,在所述副边走线的末端设置有与所述副边绕组电连通的第二组焊接点,所述第一组焊接点和所述第二组焊接点用于使所述平板变压器与所述平板变压器的外部电路连接。
  2. 根据权利要求1所述的平板变压器,其特征在于,所述原边绕组与所述副边走线之间具有预设绝缘距离,包括:
    所述绕组本体与所述副边走线之间设置有U型槽,以增加所述第一磁芯、所述第二磁芯和所述原边绕组分别与所述副边走线之间的绝缘距离。
  3. 根据权利要求2所述的平板变压器,其特征在于,所述绝缘罩内设置有绝缘片,所述绝缘片的厚与所述U型槽的槽宽相匹配,当所述绝缘罩装配好后,所述绝缘片处于所述U型槽内,以增加所述原边绕组与所述副边走线之间的绝缘距离。
  4. 根据权利要求1-3任一项所述的平板变压器,其特征在于,所述第一磁芯和所述第二磁芯分别包覆在所述PCB绕组的绕组本体两侧,形成闭合磁路,包括:
    所述绕组本体所在平面设置有通孔,所述第一磁芯和所述第二磁芯朝向所述绕组本体的一侧设置有形状与所述通孔相匹配的凸台,所述第一磁芯和所述第二磁芯的凸台对齐且具有预设气隙;
    所述第一磁芯和所述第二磁芯朝向所述PCB绕组的一侧均设置有两个边柱,所述第一磁芯和所述第二磁芯通过所述边柱闭合接触。
  5. 根据权利要求4所述的平板变压器,其特征在于,在所述PCB绕组面积最大的一面上,所述原边走线和所述副边走线所在边的长度长于所述PCB绕组本体的长度。
  6. 根据权利要求4所述的平板变压器,其特征在于,
    所述第一磁芯或所述第二磁芯与所述PCB绕组之间通过粘接胶固定连接;
    所述第二磁芯的边柱与所述第一磁芯的边柱之间通过粘接胶固定连接。
  7. 根据权利要求1-6任一项所述的平板变压器,其特征在于,所述第一磁芯与所述PCB绕组的接地点之间通过导电胶电连接。
  8. 根据权利要求1-7任一项所述的平板变压器,其特征在于,所述PCB绕组是单块多层PCB板,所述单块多层PCB板中任意两层PCB之间为绝缘介质,且任意一层PCB是原边绕组或副边绕组。
  9. 一种开关电源适配器,其特征在于,包括电源板和权利要求1-8任一项所述的平板变压器;
    所述平板变压器的第一组焊接点和第二组焊接点直接焊接在所述电源板上,且所述平板变压器的面积最大的平面垂直于所述电源板的面积最大的平面。
PCT/CN2018/113988 2017-11-09 2018-11-05 一种平板变压器及开关电源适配器 WO2019091353A1 (zh)

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CN107808756A (zh) 2018-03-16
EP3693982B1 (en) 2021-12-22
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