CN113808832A - power converter - Google Patents

Abstract

The present disclosure provides a power converter, which includes a first coil assembly, a second coil assembly, a body and an iron core assembly. The second coil assembly is electrically independent from the first coil assembly. The body includes a first accommodating space, a second accommodating space and a third accommodating space. The first accommodating space is used for accommodating at least a part of the first coil assembly. The second accommodating space is used for accommodating at least a part of the second coil assembly. The iron core assembly corresponds to the first coil assembly and the second coil assembly. At least a part of the iron core assembly is disposed in the third accommodating space of the body, and the first accommodating space is independent of the second accommodating space.

Description

Power converter

Technical Field

The present disclosure relates to a power converter. More particularly, the present disclosure relates to a power converter having an easy-to-assemble structure.

Background

A power converter (e.g., a transformer) is one of indispensable components in electronic products, and the main function of the transformer is to convert a driving voltage in an electronic circuit, such as a power transformer capable of reducing a mains voltage, and a transformer capable of increasing/decreasing a working voltage in an external power supply (AC Adapter) module used in a notebook computer, so that the specification of the transformer is very complicated, and the transformer has few fixed specifications, and is customized according to the requirements of customers.

In order to avoid electromagnetic interference generated by the coil in the transformer, a part of the transformer is provided with a metal sheet, and a lead is connected to the metal sheet by welding or pasting. However, the aforementioned welding or bonding method is generally performed only manually, which is disadvantageous for automation, and the lead is easily separated or peeled from the metal plate due to collision or poor processing, so that the effect of preventing electromagnetic interference is lost.

Therefore, how to design a power converter that can satisfy various requirements of users is a subject to be researched and solved.

Disclosure of Invention

In view of the above, the present disclosure provides a power converter to solve the above problems.

The present disclosure provides a power converter, which includes a first coil assembly, a second coil assembly, a body and an iron core assembly. The second coil assembly is electrically independent from the first coil assembly. The body comprises a first accommodating space, a second accommodating space and a third accommodating space. The first accommodating space is used for accommodating at least one part of the first coil assembly. The second accommodating space is used for accommodating at least one part of the second coil component. The iron core component corresponds to the first coil component and the second coil component. At least a part of the core assembly is disposed in the third accommodating space of the body, and the first accommodating space is independent of the second accommodating space.

According to some embodiments of the present disclosure, a cross-sectional area of a first coil unit of the first coil element is smaller than a cross-sectional area of a second coil unit of the second coil element.

According to some embodiments of the present disclosure, the cross section of the second coil unit has a rectangular structure, and an extending direction of a long axis of the rectangular structure is not perpendicular or parallel to a winding axis of the second coil unit.

According to some embodiments of the present disclosure, the power converter further includes a first covering element connected to the body to form a second accommodating space.

According to some embodiments of the present disclosure, the body has a first sidewall having a first sidewall surface, the first cover element has a second sidewall adjacent to the first sidewall, the second sidewall has a second sidewall surface, the first sidewall surface and the second sidewall surface are parallel to each other, and the first sidewall surface and the second sidewall surface are neither parallel nor perpendicular to the winding axis.

According to some embodiments of the present disclosure, the power converter further includes a protection element connected to the body, and the body is located between the core assembly and the protection element, wherein a gap is formed between the first covering element and the core assembly, and the protection element is inserted into the gap to be connected to the body.

According to some embodiments of the present disclosure, the first covering element includes at least two positioning elements, and an input end and an output end of the first coil assembly are electrically connected to the two positioning elements, respectively.

According to some embodiments of the present disclosure, the positioning member has an extending direction, when viewed along the extending direction, the first coil assembly is partially exposed, and the second coil assembly is not exposed.

According to some embodiments of the present disclosure, the first covering element and the body form an opening, and the second coil element is exposed from the opening when viewed along the extending direction.

According to some embodiments of the present disclosure, the power converter further includes a second coil assembly further including a third coil unit disposed in the second accommodating space, and the second coil unit partially overlaps the third coil unit when viewed along a direction perpendicular to the winding axis.

According to some embodiments of the present disclosure, a distance of an outermost turn of the first coil assembly from the winding axis is different from a distance of an outermost turn of the second coil assembly from the winding axis.

According to some embodiments of the present disclosure, the body is of bakelite.

According to some embodiments of the present disclosure, a thickness of an insulating layer of the first coil element is different from a thickness of an insulating layer of the second coil element.

The present disclosure provides a power converter, which forms a first accommodating space and a second accommodating space independent of each other by combining a body and a first covering element, so as to accommodate a first coil component and a second coil component respectively. Based on the structural design, the power converter disclosed by the invention does not need to reuse insulating elements such as insulating tapes and the like to reduce the interference between the coil assemblies, and has the advantages of convenience in assembly, reduction in process complexity, increase in process efficiency and the like.

In addition, the input end and the output end of the first coil component can be automatically wound on the positioning piece by using a machine, and the aim of reducing the labor cost is further fulfilled.

Drawings

The present disclosure will become more fully understood from the detailed description given herein below and the accompanying drawings. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale and are used for illustrative purposes only. In fact, the dimensions of the various features may be arbitrarily expanded or reduced for clarity of presentation.

Fig. 1 is a perspective view of a power converter according to an embodiment of the disclosure.

Fig. 2 is an exploded view of a power converter according to an embodiment of the present disclosure.

Fig. 3 is a schematic cross-sectional view of a power converter according to an embodiment of the disclosure taken along a line a-a in fig. 1.

Fig. 4 is an enlarged view of the range P in fig. 3 according to an embodiment of the present disclosure.

Fig. 5 is a schematic perspective view of a power converter according to an embodiment of the disclosure from another viewing angle.

Fig. 6 is a rear view schematic diagram of a power converter according to an embodiment of the disclosure.

Fig. 7 is a schematic front view of a power converter according to an embodiment of the disclosure.

Fig. 8 is a perspective view of a body and a first cover element according to an embodiment of the disclosure.

Fig. 9 is a front view of a power converter according to another embodiment of the present disclosure.

Fig. 10 is a schematic diagram of a partial structure of a power converter according to another embodiment of the present disclosure.

Fig. 11 is a schematic front view of a power converter according to another embodiment of the disclosure.

The reference numbers are as follows:

100 power converter

100A power converter

100B power converter

101 first coil assembly

1010 first conductor

1011 input end

1012 output terminal

102 casing

103 second coil assembly

1030 second conductive line

1031 first end

1032 a second end

103U2 second coil unit

103U3 third coil Unit

104 main body

1041 hollow tube part

1043 first side wall

1045 first sidewall surface

1047 positioning structure

106 first cover element

1061 second side wall

1063 second sidewall surface

1067 positioning structure

108 iron core component

1081 parts of the upper part

1082 lower part

1083 projecting part

1084 projecting part

1085 columnar iron core

110 first cover element

1101 positioning piece

1102 positioning piece

AS1 first accommodation space

AS2 second accommodation space

AS3 third accommodation space

AX (axial center of winding)

CA1 section

CA2 section

GP void

LX major axis

P is the range

PH is opening

X is the X axis

Y is the Y axis

Z is the Z axis

Detailed Description

In order to make the objects, features and advantages of the present disclosure more comprehensible, embodiments accompanied with figures are described in detail below. The configuration of the elements in the embodiments is illustrative and not intended to limit the disclosure. And the reference numerals in the embodiments are partially repeated, so that the relevance between different embodiments is not intended for the sake of simplifying the description. Directional terms as referred to in the following examples, for example: up, down, left, right, front or rear, etc., are directions with reference to the attached drawings only. Accordingly, the directional terminology used is intended to be in the nature of words of description rather than of limitation.

It is to be understood that the elements specifically described or illustrated may exist in various forms within the skill of one skilled in the art. Further, when a layer is "on" another layer or a substrate, it may mean "directly on" the other layer or the substrate, or that the layer is on the other layer or the substrate, or that the other layer is interposed between the other layer and the substrate.

Furthermore, relative terms, such as "lower" or "bottom" and "upper" or "top," may be used in embodiments to describe one element's relative relationship to another element as illustrated. It will be understood that if the device is turned over, with the top and bottom of the device reversed, elements described as being on the "lower" side will be turned over to elements on the "upper" side.

As used herein, the term "about" generally means within 20%, preferably within 10%, and more preferably within 5% of a given value or range. The amounts given herein are approximate, meaning that the meaning of "about" or "approximately" may still be implied without particular recitation.

Referring to fig. 1 and fig. 2, fig. 1 is a schematic perspective view of a power converter 100 according to an embodiment of the disclosure, and fig. 2 is an exploded view of the power converter 100 according to an embodiment of the disclosure. The power converter 100 may be a transformer, and includes a housing 102, a body 104, a first coil assembly 101, two second coil assemblies 103, a first cover element 106, a core assembly 108, and a first cover element 110.

In this embodiment, the first coil assembly 101 is wound around the body 104, the body 104 has a hollow cylinder 1041, and the two second coil assemblies 103 are wound around the upper and lower ends of the hollow cylinder 1041 at a winding axis AX. The first covering element 106 and the first covering element 110 are respectively connected to the upper and lower sides of the body 104.

The core assembly 108 includes an upper member 1081 and a lower member 1082, a protrusion 1083 of the upper member 1081 passes through the first cover element 106 and is inserted into the hollow cylinder 1041, and a protrusion 1084 of the lower member 1082 passes through the first cover element 110 and is inserted into the hollow cylinder 1041 to form a cylindrical core with the upper member 1081. The housing 102 is sleeved outside the core assembly 108 and the body 104 to ensure a safe and standardized distance between the first coil assembly 101, the second coil assembly 103 and an external electronic component.

In this embodiment, the body 104 may be referred to as a BOBBIN (BOBBIN), which may be made of plastic material, such as but not limited to bakelite material, to isolate the first coil element 101 and the second coil element 103 from interfering with each other.

It is noted that a first conductive line 1010 of the first coil element 101 has an insulating layer, a second conductive line 1030 of the second coil element 103 also has an insulating layer, and the thickness of the insulating layer of the first conductive line 1010 is different from the thickness of the insulating layer of the second conductive line 1030. For example, the insulation layer of the first conductive line 1010 is thick to meet the safety specification of the power converter 100.

It is noted that in some embodiments, the distance of the outermost turn of the first wire 1010 of the first coil assembly 101 from the winding axis AX is different from the distance of the outermost turn of the second wire 1030 of the second coil assembly 103 from the winding axis AX.

Referring to fig. 3, fig. 3 is a cross-sectional view of the power converter 100 taken along a line a-a in fig. 1 according to an embodiment of the disclosure. As shown in fig. 3, the protrusion 1083 and the protrusion 1084 are combined to form a cylindrical core 1085, corresponding to the first coil element 101 and the two second coil elements 103. The core assembly 108 and the body 104 form a first accommodating space AS1, and the first accommodating space AS1 is used for accommodating a portion of the first coil assembly 101.

The first cover element 106 is connected to the body 104 to form a second receiving space AS2, and the second receiving space AS2 is used for receiving a portion of the second coil element 103. It is noted that the first accommodating space AS1 is independent of the second accommodating space AS 2. In addition, a third accommodating space AS3 is formed in the hollow tube 1041 of the body 104, and a part of the core assembly 108 is disposed in the third accommodating space AS 3.

As shown in fig. 2 and fig. 3, in this embodiment, the first coil element 101 may be a single coil unit (first coil unit) formed by a first conductive wire 1010, and the first coil unit has an input end 1011 and an output end 1012. Similarly, the second coil element 103 may also be a single coil unit (second coil unit) formed by the second wire 1030, and the second coil unit has a first end 1031 and a second end 1032. An area of a cross section CA1 of the first wire 1010 of the first coil unit is smaller than an area of a cross section CA2 of the second wire 1030 of the second coil unit. Specifically, as shown in fig. 3, the cross section CA2 has a rectangular structure, and a long axis LX of the rectangular structure extends in a direction that is neither perpendicular nor parallel to the direction of the winding axis AX of the second wire 1030.

Referring to fig. 3 and 4, fig. 4 is an enlarged view of a range P in fig. 3 according to an embodiment of the disclosure. As shown, the body 104 has a first sidewall 1043, the first sidewall 1043 has a first sidewall surface 1045, the first cover element 106 has a second sidewall 1061 adjacent to and abutting the first sidewall 1043, and the second sidewall 1061 has a second sidewall surface 1063. The first side wall surface 1045 and the second side wall surface 1063 are parallel to each other, and the first side wall surface 1045 and the second side wall surface 1063 are not parallel nor perpendicular to the winding axis AX. Based on the design of the first and second sidewalls 1043 and 1061, the assembly accuracy can be improved and the safety specification distance of the power converter 100 can be ensured.

Referring to fig. 3 and 5, fig. 5 is a schematic perspective view of a power converter 100 according to an embodiment of the disclosure from another viewing angle. In this embodiment, the housing 102, which may be referred to as a protection element, is connected to the body 104, and as shown in fig. 3, the body 104 is located between the core assembly 108 and the housing 102 (protection element). As shown in fig. 5, a gap GP is formed between the first cover member 106 and the core member 108, and the housing 102 (protection member) is inserted into the gap GP to be connected to the body 104. The housing 102 is made of a non-conductive material, such as polyethylene terephthalate (PET), but is not limited thereto, and may be made of bakelite, for example.

Referring back to fig. 1 and 2, the first covering element 110 and the first covering element 106 may include a plurality of positioning members, which may be pins, extending along an extending direction, such as a-Y axis direction. The input end 1011 and the output end 1012 of the first coil assembly 101 are electrically connected to the positioning element 1101 and the positioning element 1102, respectively.

Referring to fig. 6, fig. 6 is a rear view of a power converter 100 according to an embodiment of the disclosure. As shown in fig. 6, when viewed in the extending direction (-Y-axis direction), the first coil assembly 101 is partially exposed, and the second coil assembly 103 is not exposed.

Referring to fig. 7, fig. 7 is a schematic front view of a power converter 100 according to an embodiment of the disclosure. The first covering element 106 and the body 104 form an opening PH, and the second coil element 103 exposes the opening PH when viewed along the Y-axis (or the extending direction).

When the power converter 100 is mounted on a circuit board (not shown), the positioning members are inserted into the circuit board to be positioned and electrically connected, and the first end 1031 and the second end 1032 of the second coil element 103 may also be electrically connected to electrical contacts on the circuit board, for example, by soldering. In this embodiment, the first coil element 101 may be a primary side (primary side) with an input voltage of, for example, 400 volts, and the second coil elements 103 may be connected in series through the circuit board to serve as a secondary side (secondary side) with an output voltage of, for example, 12 volts. The power converter 100 of the present disclosure may be used in a desktop computer or a computer for electronic contests.

Referring to fig. 8, fig. 8 is a perspective view of the body 104 and the first covering element 106 according to an embodiment of the disclosure. In this embodiment, the first covering element 106 has a positioning structure 1067, the end of the hollow cylinder 1041 has a corresponding positioning structure 1047, and the positioning structure 1067 is a convex triangle and is combined with the concave triangle positioning structure 1047. Based on the design of the positioning structure, the assembling positioning accuracy of the first cover element 106 and the body 104 can be increased, and the first cover element 106 can also be prevented from rotating relative to the body 104.

Referring to fig. 9 and 10, fig. 9 is a front view of a power converter 100A according to another embodiment of the disclosure, and fig. 10 is a partial structure diagram of the power converter 100A according to another embodiment of the disclosure. In this embodiment, the second coil assembly 103 includes two coil units (the second coil unit 103U2 and the third coil unit 103U3), which are disposed in the second accommodating space AS 2. As shown in fig. 10, the second coil unit 103U2 partially overlaps the third coil unit 103U3 when viewed along a direction (Y-axis) perpendicular to the winding axis AX.

Referring to fig. 11, fig. 11 is a schematic front view of a power converter 100B according to another embodiment of the present disclosure. In this embodiment, the power converter 100B may be formed by combining one or more bodies 104, a first covering element 106 and a first covering element 110, and may accommodate three first coil elements 101 and four second coil elements 103. Three first coil elements 101 may be connected in series, and four second coil elements 103 may be connected in parallel through the circuit board, thereby achieving the purposes of increasing the conductive efficiency of the power converter 100B, reducing the temperature and reducing the leakage current.

The present disclosure provides a power converter, which forms a first accommodating space AS1 and a second accommodating space AS2 independent from each other by combining a body 104 and first covering elements 106 and 110, so AS to accommodate a first coil element 101 and a second coil element 103, respectively. Based on the structural design, the power converter disclosed by the invention does not need to reuse insulating elements such as insulating tapes and the like to reduce the interference between the coil assemblies, and has the advantages of convenience in assembly, reduction in process complexity, increase in process efficiency and the like.

In addition, the input end 1011 and the output end 1012 of the first coil assembly 101 can be automatically wound on the positioning members 1101 and 1102 by a machine, thereby further achieving the purpose of reducing labor cost.

Although the embodiments of the present disclosure and their advantages have been disclosed above, it should be understood that various changes, substitutions and alterations can be made herein by those skilled in the art without departing from the spirit and scope of the disclosure. Moreover, the scope of the present disclosure is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification, but rather, the process, machine, manufacture, composition of matter, means, methods and steps, presently existing or later to be developed, that will be obvious to one having the benefit of the present disclosure, may be utilized in the practice of the present disclosure. Accordingly, the scope of the present disclosure includes the processes, machines, manufacture, compositions of matter, means, methods, and steps described above. In addition, each claim constitutes a separate embodiment, and the scope of protection of the present disclosure also includes combinations of the respective claims and embodiments.

Claims (13)

1. A power converter, comprising:

a first coil assembly;

a second coil assembly electrically independent from the first coil assembly;

a body, comprising:

a first accommodating space for accommodating at least a part of the first coil assembly;

a second accommodating space for accommodating at least a portion of the second coil element; and

a third accommodating space; and

an iron core component corresponding to the first coil component and the second coil component;

wherein at least a part of the core assembly is disposed in the third accommodating space of the body, and the first accommodating space is independent of the second accommodating space.

2. The power converter of claim 1 wherein a cross-sectional area of a first coil unit of the first coil element is smaller than a cross-sectional area of a second coil unit of the second coil element.

3. The power converter as claimed in claim 2, wherein the cross section of the second coil unit has a rectangular structure, and an extending direction of a long axis of the rectangular structure is not perpendicular or parallel to a winding axis of the second coil unit.

4. The power converter as claimed in claim 3, wherein the power converter further comprises a first covering element connected to the body to form the second receiving space.

5. The power converter of claim 4 wherein the body has a first sidewall having a first sidewall surface, the first cover element has a second sidewall adjacent to the first sidewall, the second sidewall has a second sidewall surface, the first sidewall surface and the second sidewall surface are parallel to each other, and the first sidewall surface and the second sidewall surface are neither parallel nor perpendicular to the winding axis.

6. The power converter as claimed in claim 4, wherein the power converter further comprises a protection element connected to the body, and the body is located between the core assembly and the protection element, wherein a gap is formed between the first covering element and the core assembly, and the protection element is inserted into the gap to connect with the body.

7. The power converter as claimed in claim 4, wherein the first covering element comprises at least two positioning elements, and an input terminal and an output terminal of the first coil element are electrically connected to the two positioning elements, respectively.

8. The power converter of claim 7 wherein the positioning member has an extending direction, and when viewed along the extending direction, the first coil element is partially exposed and the second coil element is not exposed.

9. The power converter as claimed in claim 8, wherein the first covering element and the body form an opening, and the second coil element is exposed from the opening when viewed along the extending direction.

10. The power converter of claim 4, wherein the power converter further comprises a third coil unit disposed in the second accommodating space and partially overlapping the third coil unit when viewed along a direction perpendicular to the winding axis.

11. The power converter of claim 4 wherein the outermost turn of the first coil element is a different distance from the winding axis than the outermost turn of the second coil element.

12. The power converter of claim 1, wherein the body is made of bakelite.

13. The power converter of claim 1 wherein a thickness of an insulating layer of the first coil element is different from a thickness of an insulating layer of the second coil element.

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