CN101241798A - Leakage inductance adjustable transformer - Google Patents
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- CN101241798A CN101241798A CNA2007101882023A CN200710188202A CN101241798A CN 101241798 A CN101241798 A CN 101241798A CN A2007101882023 A CNA2007101882023 A CN A2007101882023A CN 200710188202 A CN200710188202 A CN 200710188202A CN 101241798 A CN101241798 A CN 101241798A
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 199
- 230000004907 flux Effects 0.000 claims abstract description 101
- 238000000034 method Methods 0.000 claims abstract description 55
- 239000002184 metal Substances 0.000 claims description 6
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- 239000003990 capacitor Substances 0.000 description 3
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Abstract
Description
技术领域technical field
本发明涉及一种变压器,特别是涉及一种在制造时,容许一铁心组的铁心可以相对移动的制程可调漏感型变压器。The invention relates to a transformer, in particular to a process-adjustable leakage inductance transformer which allows the iron cores of a core group to move relatively during manufacture.
背景技术Background technique
如图1所示,为一般使用在一背光模块的变压器100结构,该变压器100包含一铁心单元11、一结合于该铁心单元11的绕线架单元12、一设置于该绕线架单元12的初级线圈13,及一设置于该绕线架单元12的次级线圈14,每一个背光模块都包含多个变压器100来点亮多支灯管,为了使每支灯管的亮度一致,每一个变压器100与灯管连接的次级线圈14应尽可能具有相同的电感值,借此才能达到电流平均、灯管亮度一致的使用目的。As shown in Figure 1, it is a
然而,实际制造时该铁心单元11往往会产生极大误差,原因在于该铁心单元11是属于无空气隙磁芯,烧结制造时又有许多变量影响,所以当一个变压器100制造完成后,经过测试可以发现电感值误差范围高达40%,漏电感值误差范围高达10%,这与出货要求的误差范围1%相距甚远,如果再透过后续研磨、加工等方式来改善不良品,也会消耗大量的后续加工时间,以至于有许多产品都在筛选过程中被直接丢弃不用,产生极低的良率,并使得整体的成本大幅增加。However, the
此外,由于一般铁心单元11都是由两个以上的铁心组件111组合而成,如图1中所述铁心组件111分别是I形与O形,当采用相互抵接的EE形结构时,如果要将铁心位置移动做调整,这会使中间初级线圈的位置产生气隙,造成大量的泄漏磁通,于是会大幅影响电力输出,所以不适合用气隙方式来进行调整工作,而综观目前一般的铁心单元11设计,都无法在保持该初级磁通稳定不变的状态下,还能达到对次级磁通量进行调整改变的功效。In addition, because the
发明内容Contents of the invention
本发明的目的是在于提供一种制造时,可以通过调整漏电感值的结构设计,使得每一个变压器的漏电感误差范围能通过调整达到出货标准,进而可以大幅提高制程良率的制程可调漏感型变压器。The purpose of the present invention is to provide a structural design that can adjust the leakage inductance value during manufacturing, so that the error range of the leakage inductance of each transformer can be adjusted to reach the shipping standard, and then the process yield can be greatly improved. Leakage-inductance transformers.
该制程可调漏感型变压器包含一绕线架单元、一初级线圈、一次级线圈,及一铁心单元。该初、次级线圈都是设置于该绕线架单元。该铁心单元是组设于该绕线架单元并形成一连接该初级线圈与该次级线圈的磁通路。The process adjustable leakage inductance transformer includes a winding frame unit, a primary coil, a secondary coil and an iron core unit. Both the primary and secondary coils are arranged on the bobbin unit. The core unit is assembled on the bobbin unit and forms a magnetic path connecting the primary coil and the secondary coil.
本发明的特征在于:该铁心单元包括一第一铁心、一连接于该第一铁心的第二铁心、一形成于该第一铁心与该第二铁心之间并靠近该初级线圈的初级磁通区,及一形成于该第一铁心与该第二铁心之间并靠近该次级线圈的次级磁通区,该绕线架单元在该铁心单元的周围预留有容许该第一、二铁心相对移动的空间,该初级磁通区的有效磁通面积与该次级磁通区的有效磁通面积不相等,且容许在该第一、二铁心相对移动下改变该次级磁通区与保持该初级磁通区。The feature of the present invention is that the core unit includes a first core, a second core connected to the first core, a primary magnetic flux formed between the first core and the second core and close to the primary coil area, and a secondary magnetic flux area formed between the first core and the second core and close to the secondary coil, the bobbin unit is reserved around the core unit to allow the first, second The space where the iron core moves relative to each other, the effective magnetic flux area of the primary magnetic flux area is not equal to the effective magnetic flux area of the secondary magnetic flux area, and the secondary magnetic flux area is allowed to change under the relative movement of the first and second iron cores and maintain the primary flux region.
本发明的有益效果在于:制造时如果发现该次级线圈的电感值与出货标准有误差,则可以借由该第一、二铁心相对移动的设计来改变该次级线圈的泄漏磁通量,进而就能使得该次级线圈的电感值能达到出货标准,并达到大幅提高制程良率的使用目的。The beneficial effect of the present invention is that: if the inductance value of the secondary coil is found to be in error with the shipping standard during manufacture, the leakage magnetic flux of the secondary coil can be changed by means of the design of the relative movement of the first and second iron cores, and then Therefore, the inductance value of the secondary coil can reach the delivery standard, and the purpose of greatly improving the process yield can be achieved.
附图说明Description of drawings
图1是一示意图,说明一般的变压器结构;Figure 1 is a schematic diagram illustrating a general transformer structure;
图2是一示意图,说明本发明制程可调漏感型变压器的第一较佳实施例;Fig. 2 is a schematic diagram illustrating the first preferred embodiment of the process-adjustable leakage inductance transformer of the present invention;
图3是一示意图,说明该第一较佳实施例中,一第一铁心与一第二铁心的组成情形;Fig. 3 is a schematic diagram illustrating the composition of a first iron core and a second iron core in the first preferred embodiment;
图4是一示意图,说明该第一较佳实施例中,该第一铁心凸出该第二铁心的情形;Fig. 4 is a schematic diagram illustrating the situation in which the first iron core protrudes from the second iron core in the first preferred embodiment;
图5是一示意图,说明本发明制程可调漏感型变压器的第二较佳实施例;Fig. 5 is a schematic diagram illustrating the second preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图6是一示意图,说明上述第二较佳实施例中,该第二铁心的另一种结构变化;Fig. 6 is a schematic diagram illustrating another structural variation of the second core in the above-mentioned second preferred embodiment;
图7是一示意图,说明本发明制程可调漏感型变压器的第三较佳实施例;Fig. 7 is a schematic diagram illustrating the third preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图8是一示意图,说明本发明制程可调漏感型变压器的第四较佳实施例;Fig. 8 is a schematic diagram illustrating the fourth preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图9是一示意图,说明本发明制程可调漏感型变压器的第五较佳实施例;Fig. 9 is a schematic diagram illustrating the fifth preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图10是一示意图,说明本发明制程可调漏感型变压器的第六较佳实施例;Fig. 10 is a schematic diagram illustrating the sixth preferred embodiment of the process-adjustable leakage inductance transformer of the present invention;
图11是一示意图,说明本发明制程可调漏感型变压器的第七较佳实施例;Fig. 11 is a schematic diagram illustrating the seventh preferred embodiment of the process-adjustable leakage inductance transformer of the present invention;
图12是一示意图,说明本发明制程可调漏感型变压器的第八较佳实施例;Fig. 12 is a schematic diagram illustrating the eighth preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图13是一示意图,说明本发明制程可调漏感型变压器的第九较佳实施例;Fig. 13 is a schematic diagram illustrating the ninth preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图14是一示意图,说明本发明制程可调漏感型变压器的第十较佳实施例;Fig. 14 is a schematic diagram illustrating the tenth preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图15是一示意图,说明本发明制程可调漏感型变压器的第十一较佳实施例;Fig. 15 is a schematic diagram illustrating an eleventh preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图16是一示意图,说明本发明制程可调漏感型变压器的第十二较佳实施例;Fig. 16 is a schematic diagram illustrating a twelfth preferred embodiment of the process adjustable leakage inductance transformer of the present invention;
图17是一示意图,说明本发明制程可调漏感型变压器的第十三较佳实施例;Fig. 17 is a schematic diagram illustrating a thirteenth preferred embodiment of the process-adjustable leakage inductance transformer of the present invention;
图18是一示意图,说明该第十三较佳实施例中的组合情形;Fig. 18 is a schematic diagram illustrating the combination situation in the thirteenth preferred embodiment;
图19是一示意图,说明本发明制程可调漏感型变压器的第十四较佳实施例;及Fig. 19 is a schematic diagram illustrating the fourteenth preferred embodiment of the process-adjustable leakage inductance transformer of the present invention; and
图20是一示意图,说明该第十四较佳实施例中的组成结构。Fig. 20 is a schematic diagram illustrating the constitution of the fourteenth preferred embodiment.
具体实施方式Detailed ways
下面结合附图及实施例对本发明进行详细说明:Below in conjunction with accompanying drawing and embodiment the present invention is described in detail:
在本发明被详细描述前,要注意的是,以下的说明内容中,类似的组件是以相同的编号来表示。Before the present invention is described in detail, it should be noted that in the following description, similar components are denoted by the same numerals.
如图2、3、4所示,本发明制程可调漏感型变压器200的第一较佳实施例包含一绕线架单元20、一初级线圈30、一次级线圈40,及一铁心单元50。As shown in Figures 2, 3 and 4, the first preferred embodiment of the process adjustable
该初、次级线圈30、40都是设置于该绕线架单元20。The primary and
该铁心单元50是组设于该绕线架单元20并形成一连接该初级线圈30与该次级线圈40的磁通路,该铁心单元50包括一第一铁心51、一连接于该第一铁心51的第二铁心52、一形成于该第一铁心51与该第二铁心52之间并靠近该初级线圈30的初级磁通区53(以相互重叠的阴影表示),及一形成于该第一铁心51与该第二铁心52之间并靠近该次级线圈40的次级磁通区54(同样以相互重叠的阴影表示)。The
该绕线架单元20包括一沿一长方向X延伸的穿孔21、两个分别对应于该第一铁心51两端的预留空间22或开口,及一埋设于内的导电片23。The
所述预留空间22或开口在本实施例中是指形成在该第一铁心51两端沿移动方向(该长方向X)的开放空间(以假想线框示意),该绕线架单元20在设计时就必须规划所述预留空间22以容许该第一铁心51、第二铁心52能相对移动,在本实施例中所述预留空间22是容许该第一铁心51沿着该长方向X移动。The
该导电片23是与该初级线圈30、次级线圈40的其中一者电连接并面向一电路板201上的金属部90,该导电片23与该金属部90是等效界定出一电容C,该电容C可提供保护电路(图未示)的检知运用,并达到可额外增加电容组件的使用效果。The
该第一铁心51是穿设于该绕线架单元20的穿孔21,并两端形成有与该第二铁心52相连的初级磁通区53、次级磁通区54,该第一铁心51是I形铁心,它的长度d1在本实施例中是大于该初级磁通区53与该次级磁通区54之间的最大长度d2,借以使得该第一铁心51的一部份可以延伸出该穿孔21,而延伸出的部分可以方便工作人员接触以进行调整工作,同时也能达到扩大或缩小该次级磁通区54又不改变该初级磁通区53的功效。The
该第二铁心52是沿一垂直方向Z叠置于该第一铁心51,该第二铁心52具有二分别对应于该第一铁心51两端的凹孔521,该初级磁通区53与该次级磁通区54是分别形成于该第一铁心51与该第二铁心52所接触的两个端部,如图2所示该初级磁通区53的有效磁通面积小于该次级磁通区54的有效磁通面积,而在该第一铁心51沿该长方向X移动下能使得该次级磁通区54的有效磁通面积改变,以及该初级磁通区53的有效磁通面积不变,进而就能改变该次级磁通区54的磁阻,使得漏电感的误差范围降至1%,于是就能达到出货标准的要求。The
借此,制造时如果发现该次级线圈40的电感值与出货标准有误差,则可以通过该第一铁心51、第二铁心52相对移动的设计来改变该次级线圈40的泄漏磁通量,调整完成后再点胶固定,进而就能使得该次级线圈40的漏电感值能达到出货标准,并达到大幅提高制程良率的使用目的。In this way, if the inductance value of the
如图5所示,以下将更进一步说明本发明制程可调漏感型变压器200的第二较佳实施例,该第二较佳实施例与上述该第一较佳实施例大致相同,其不同处在于该变压器200包含两个初级线圈30与两个次级线圈40,该绕线架单元20包括两个相互连结的绕线架24,所述初级线圈30是分别设置于所述绕线架24上且彼此相邻,所述次级线圈40是分别设置于所述绕线架24上且相互远离,该第一铁心51具有沿该长方向X呈宽度不等的一厚宽度段511,及两个分别从该厚宽度段511两端延伸的薄宽度段512,该厚宽度段511是对应于在中间位置的初级线圈30,所述薄宽度段512是对应于所述次级线圈40,借由宽度的不同可以形成不同的磁阻,再配合该第一铁心51沿该长方向X移动就可以在无气隙的状态下产生更丰富的磁阻变化,进而调整泄漏磁通量,使得漏电感值能达到出货要求。As shown in Fig. 5, the second preferred embodiment of the process adjustable
上述中,该第二铁心52是由两个呈“日”形结构的铁心块520组成,实际制造时,所述铁心块520也可以改由O形结构,如同配合图6所示,该第二铁心52还可以是一个能同时与所述绕线架2 4组合且呈O形的铁心,由此可知该第二铁心52能够制作成多种结构变化,而无论采用何种结构变化都可以在本发明的技术旨趣条件下与该第一铁心51达到可调整漏电感值的功效。In the above, the
如图7所示,以下将更进一步说明本发明制程可调漏感型变压器200的第三较佳实施例,由于以下各实施例主要改变是该铁心单元50采用不同设计,因此省略绕线架结构并以假想线示意各该初级线圈30、次级线圈40,该第三较佳实施例与上述该第二较佳实施例大致相同,其不同处在于该铁心单元50还包括一第四铁心55,该第一铁心51是I形铁心,该第二铁心52、第四铁心55是沿该长方向X连接成O形且沿该垂直方向Z叠置于该第一铁心51上的C形铁心,所述初级线圈30、次级线圈40是围绕于该第一铁心51,该第二铁心52、第四铁心55各具有一对应于该第一铁心51端部的凹孔521、551,该初级磁通区53与该次级磁通区54是分别形成于该第一铁心51与该第二铁心52、第四铁心55所接触的端部,制造时,该第一铁心51可沿该长方向X移动以调整漏电感达到出货要求。As shown in Figure 7, the third preferred embodiment of the process adjustable
如图8所示,以下将更进一步说明本发明制程可调漏感型变压器200的第四较佳实施例,该第四较佳实施例与上述该第二较佳实施例大致相同,其不同处在于该铁心单元50的第二铁心52是沿一垂直方向Z延伸并沿该垂直方向Z叠置于该第一铁心51的C形铁心,该初级磁通区53与该次级磁通区54是分别形成于该第一铁心51与该第二铁心52所接触的两端部,制造时,该第一铁心51可沿该长方向X移动以调整漏电感达到出货要求。As shown in FIG. 8 , the fourth preferred embodiment of the process adjustable
如图9所示,以下将更进一步说明本发明制程可调漏感型变压器200的第五较佳实施例,该第五较佳实施例与上述该第四较佳实施例大致相同,其不同处在于该铁心单元的第二铁心52是沿一横方向Y延伸并沿一垂直方向Z叠置于该第一铁心51的U形铁心,该初级磁通区53与该次级磁通区54是分别形成于该第一铁心51与该第二铁心52所接触的两端部,制造时,该第一铁心51可沿该长方向X移动以调整漏电感达到出货要求。As shown in FIG. 9, the fifth preferred embodiment of the process adjustable
如图10所示,以下将更进一步说明本发明制程可调漏感型变压器200的第六较佳实施例,该第六较佳实施例的不同处在于该铁心单元50包括一呈E形且连接于该第一铁心51的第二铁心52,及一形成于该第一铁心与该第二铁心之间的可调磁通区55,制造时,该第一铁心51可沿该长方向X移动以改变该可调磁通区55,进而调整漏电感达到出货要求。As shown in FIG. 10, the sixth preferred embodiment of the process adjustable
如图11所示,以下将更进一步说明本发明制程可调漏感型变压器200的第七较佳实施例,该第七较佳实施例与上述该第六较佳实施例大致相同,其不同处在于该铁心单元50的第二铁心52具有三个沿一长方向X延伸的第二延伸段522,及一连接于所述第二延伸段522的第二连接段523,该第一铁心51是可沿一垂直于该长方向X的横方向Y移动地设置于所述第二延伸段522末端,其中位于两侧的第二延伸段522与该第一铁心51形成两个可调磁通区55,制造时,该第一铁心51可沿该横方向Y移动以改变所述可调磁通区55,进而调整漏电感达到出货要求。As shown in FIG. 11, the seventh preferred embodiment of the process adjustable
如图12所示,以下将更进一步说明本发明制程可调漏感型变压器200的第八较佳实施例,该第八较佳实施例与上述该第七较佳实施例大致相同,其不同处在于该铁心单元50的第二铁心52具有三个沿一横方向Y延伸的第二延伸段522,及一连接于所述第二延伸段522的第二连接段523,该第一铁心51是可沿该长方向X移动地设置于所述第二延伸段522末端,并具有一缺口513是围绕于位在中间的第二延伸段522,该缺口513与该第二延伸段522之间留有气隙以形成该可调磁通区,且该缺口513沿该长方向X的宽度比该第二延伸段522要宽。As shown in Fig. 12, the eighth preferred embodiment of the process adjustable
如图13所示,以下将更进一步说明本发明制程可调漏感型变压器200的第九较佳实施例,该第九较佳实施例与上述该第八较佳实施例大致相同,其不同处在于该第一铁心具有沿该长方向X呈宽度不等的一厚宽度段511,及一薄宽度段512,其中位在中间的第二延伸段522是对应于该薄宽度段512且两者之间留有气隙以形成中心泄漏式的可调磁通区55。As shown in FIG. 13 , the ninth preferred embodiment of the process adjustable
如图14所示,以下将更进一步说明本发明制程可调漏感型变压器200的第十较佳实施例,该第十较佳实施例与上述该第九较佳实施例大致相同,其不同处在于该第一铁心51具有沿该长方向X呈宽度不等的一厚宽度段511,及一从该厚宽度段511沿该长方向X呈宽度渐缩的宽度渐缩段514,其中位在中间的第二延伸段522是对应于该宽度渐缩段514。As shown in FIG. 14, the tenth preferred embodiment of the process adjustable
如图15所示,以下将更进一步说明本发明制程可调漏感型变压器200的第十一较佳实施例,该第十一较佳实施例的不同处在于该第一铁心51、第二铁心52都是E形铁心,并各具有三个第一延伸段515、第二延伸段522,所述第一延伸段515、第二延伸段522是彼此交错地相连,且位于中间的第一延伸段515、第二延伸段522之间形成有该可调磁通区55与设有该初级线圈30、次级线圈40,该第一铁心51、第二铁心52可沿该长方向X移动而改变泄漏电感。As shown in FIG. 15, the eleventh preferred embodiment of the process adjustable
如图16所示,以下将更进一步说明本发明制程可调漏感型变压器200的第十二较佳实施例,该第十二较佳实施例与上述该第九较佳实施例大致相同,其不同处在于该第一铁心51具有三个形成于该第一延伸段515末端的缺口516,该第二铁心52具有三个形成于该第二延伸段522末端的缺口523,所述第一延伸段515、第二延伸段522末端的缺口516、523是彼此对合相连,且位于中间对合的所述缺口形成有该可调磁通区55,该第一铁心51、第二铁心52可沿该长方向X移动而改变泄漏电感。As shown in FIG. 16 , the twelfth preferred embodiment of the process adjustable
如图17、18所示,以下将更进一步说明本发明制程可调漏感型变压器200的第十三较佳实施例,该第十三较佳实施例的不同处在于该铁心单元50还包括一第三铁心56,该第一铁心51、第三铁心56是沿该垂直方向Z叠置的I形铁心,该第二铁心52是O形铁心,并具有两个相间隔的开口524,该第一铁心51、第三铁心53是分别穿伸于所述开口524中,该初级磁通区53与该次级磁通区54是分别形成于该第一铁心51、第三铁心56与该第二铁心52所接触的两个端部,该第一铁心51、第三铁心56可沿该长方向X相对移动而达到调整泄漏电感的功效。As shown in Figures 17 and 18, the thirteenth preferred embodiment of the process adjustable
如图19、20所示,以下将更进一步说明本发明制程可调漏感型变压器200的第十四较佳实施例,该第十四较佳实施例与该第十一较佳实施例大致相同,不同处在于该绕线架单元20包括两个相互连结的绕线架24,该第一铁心51、第三铁心56是沿该长方向X并排的I形铁心,该第二铁心52是O形铁心并具有两个相间隔的开口524,该第一铁心51、第三铁心56的两端都是对应于所述开口524中,该初级磁通区53与该次级磁通区54是分别形成于该第一铁心51、第三铁心56与该第二铁心52所接触的两个端部,该第一铁心51、第三铁心56可沿该长方向X相对移动而达到调整泄漏电感的功效。As shown in Figures 19 and 20, the fourteenth preferred embodiment of the process adjustable
值得一提的是,上述各该较佳实施例中,无论是一组初级线圈30、次级线圈40的设计,或是多组初级线圈30、次级线圈40的设计,以及不同铁心单元50结构的设计,本发明都能通过改变该绕线架单元20与该铁心单元50结构的方式,让制造人员能在保持该初级磁通区53的有效磁通面积不改变、稳定的状态下,还能对该次级磁通区54、磁通量进行调整的功效,进而能达到调整所有变压器的漏电感值符合出货标准的功效。It is worth mentioning that, in each of the above-mentioned preferred embodiments, whether it is the design of one set of
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101640113B (en) * | 2009-07-02 | 2011-10-19 | 昆山贯捷电子有限公司 | Transformer, bobbin bracket and backlight module using the transformer |
CN102376438A (en) * | 2010-07-02 | 2012-03-14 | 三星电机株式会社 | Transformer |
US8648685B2 (en) | 2010-07-02 | 2014-02-11 | Samsung Electro-Mechanics Co., Ltd. | Transformer and flat panel display device including the same |
US8742878B2 (en) | 2010-07-02 | 2014-06-03 | Samsung Electro-Mechanics Co., Ltd. | Transformer and flat panel display device including the same |
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CN1581381A (en) * | 2003-08-14 | 2005-02-16 | 耀胜电子股份有限公司 | Leakage inductance adjustable transformer |
CN2755746Y (en) * | 2004-12-06 | 2006-02-01 | 钟玉麟 | Transformers for resonant converters |
CN100543891C (en) * | 2006-02-14 | 2009-09-23 | 台达电子工业股份有限公司 | Transformer structure |
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2007
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101640113B (en) * | 2009-07-02 | 2011-10-19 | 昆山贯捷电子有限公司 | Transformer, bobbin bracket and backlight module using the transformer |
CN102376438A (en) * | 2010-07-02 | 2012-03-14 | 三星电机株式会社 | Transformer |
US8648685B2 (en) | 2010-07-02 | 2014-02-11 | Samsung Electro-Mechanics Co., Ltd. | Transformer and flat panel display device including the same |
US8698587B2 (en) | 2010-07-02 | 2014-04-15 | Samsung Electro-Mechanics Co., Ltd. | Transformer |
US8742878B2 (en) | 2010-07-02 | 2014-06-03 | Samsung Electro-Mechanics Co., Ltd. | Transformer and flat panel display device including the same |
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