CN114078625B - Transformer - Google Patents

Abstract

The present invention relates to a transformer, which comprises: an inner frame; a plurality of primary coils wound on the inner frame; a plurality of primary terminal pins protruding from one side of the inner frame and connected to the end leads of the primary coils; an outer frame combined with the inner frame; a plurality of secondary coils wound on the outer frame; and a plurality of secondary terminal pins protruding from one side of the outer frame in a direction opposite to the direction in which the primary coils protrude from the inner frame in a manner separated from each other and connected to the end leads of the secondary coils, wherein each of the secondary terminal pins is connected to a lead. The present invention has the following advantages, namely, a plurality of different output voltages can be obtained from one transformer and the insulation distance between the terminal pins can be ensured, and the winding and connection can be automatic.

Description

transformer

Technical Field

The present invention relates to a transformer, and more particularly, to a transformer provided with a plurality of secondary coils in order to obtain a plurality of voltages required by various components.

Background Art

A transformer is a device used to convert electricity to a desired value.

The transformer includes a primary coil and a secondary coil that are magnetically coupled. The basic principle is that when current flows in the primary coil, current can flow in the secondary coil due to electromagnetic induction. The ratio of the voltage of the primary coil and the voltage transmitted to the secondary coil corresponds to the ratio of the number of turns of the winding coil.

This transformer can obtain any desired output voltage by directing voltage around the secondary coil through the magnetic field around the primary coil and changing the ratio of the number of turns wound on the coil.

Also, in order to obtain a plurality of output voltages from one transformer, the transformer may obtain a plurality of mutually different voltages by winding a plurality of secondary coils and combining the primary coil and the secondary coil.

FIG. 1 shows an existing transformer that can obtain a variety of different voltages.

As shown in FIG. 1 , a conventional transformer 1 has a structure in which four terminal pins 3 are formed on the primary coil, six terminal pins 5 are formed on the secondary coil, two coils are wound on the primary bobbin, and four coils are wound on the secondary bobbin.

In the transformer 1, the copper wires at both ends of the two primary coils wound on the primary frame are respectively wound around the terminal pins 3 of No. 1 to No. 2 and No. 4 to No. 6 and fixed by welding, and the copper wires at both ends of the four secondary coils wound on the secondary frame are respectively wound around the terminal pins 5 of No. 7 to No. 12, No. 8 to No. 12, No. 11 to No. 9, and No. 11 to No. 10 and fixed by welding. This transformer 1 can obtain a variety of different output voltages by selectively combining the two primary coils and the four secondary coils.

However, in the case of thick copper wires, the existing transformer 1 has problems such as short circuits due to difficulty in ensuring the insulation distance between the terminal pins. Therefore, as a solution, multiple thin copper wires can be used to connect multiple copper wires to one terminal pin. In this case, multiple copper wires are connected to each terminal pin. Therefore, there is a risk of short circuits due to difficulty in ensuring the insulation distance between the terminal pins and the problem of unstable withstand voltage.

Furthermore, since a plurality of copper wires are connected to one terminal pin, the conventional transformer 1 has the risk of local heating and the problem of reduced efficiency due to the generation of a current bottleneck.

Furthermore, since a plurality of copper wires are connected to one terminal pin, the conventional transformer 1 has a problem that automatic winding and automatic connection are difficult.

Summary of the invention

An object of the present invention is to provide a transformer that can obtain a plurality of different output voltages from one transformer, can ensure the insulation distance (safety distance) between terminal pins, and can realize automatic winding and automatic connection.

Another object of the present invention is to provide a transformer capable of ensuring insulation by shielding copper wires connected to terminal pins.

In order to achieve the above-mentioned purpose, the present invention is characterized in that it includes: a main body; and a core, which is combined with the above-mentioned main body, and the above-mentioned main body includes: an inner frame; a primary coil, which is wound on the above-mentioned inner frame; a plurality of primary terminal pins, which are formed on one side of the above-mentioned inner frame and are connected to the end lead of the above-mentioned primary coil; an outer frame, which is combined with the above-mentioned inner frame; a plurality of secondary coils, which are wound on the above-mentioned outer frame; and a plurality of secondary terminal pins, which are formed on the other side of the above-mentioned outer frame in the opposite direction to the direction in which the above-mentioned primary terminal pins protrude from the above-mentioned inner frame, and are connected to the end lead of the above-mentioned secondary coil, and the above-mentioned plurality of secondary terminal pins are formed on the other side of the above-mentioned outer frame in an upper and lower separated manner, and each of the above-mentioned secondary terminal pins is connected to an end lead of the above-mentioned secondary coil.

The primary terminal pin is bent downward and protrudes downward from the lower surface of the body.

The above-mentioned secondary terminal pin includes: a lower secondary terminal pin, which is bent downward and protrudes downward from the lower surface of the above-mentioned main body; and an upper secondary terminal pin, which is formed on the other side of the above-mentioned outer frame, is on the upper part of the above-mentioned lower secondary terminal pin and is bent downward, and is separated from the above-mentioned lower secondary terminal pin and arranged side by side.

The number of the lower secondary terminal pins is the same as the number of the upper secondary terminal pins.

The upper secondary terminal pin is longer than the lower secondary terminal pin, and ends of the upper secondary terminal pin and the lower secondary terminal pin are located at the same height.

The plurality of secondary terminal pins formed on the outer frame are formed in pairs symmetrically with each other in the up-down direction, and one of the secondary coils is connected to every two secondary terminal pins in the up-down direction.

The inner frame is formed by a first forming part.

A portion of the primary terminal pins connected to the primary coil and the end leads of the primary coil is located inside the first molded portion, and the remaining portion of the primary terminal pins protrudes outside the first molded portion.

The above-mentioned outer frame includes: a secondary winding part, on which a secondary coil is wound; an upper flange and a lower flange, respectively formed on both sides of the above-mentioned secondary winding part, for forming a winding space therebetween; and a plurality of locking grooves, formed on the above-mentioned upper flange and the above-mentioned lower flange, for locking and supporting the end leads of the above-mentioned secondary coil wound on the above-mentioned secondary winding part before being connected to the above-mentioned secondary terminal pins.

The secondary terminal pins are formed to protrude from the upper flange and the lower flange corresponding to both sides of the locking groove.

The length of the secondary terminal pins protruding from the upper flange is longer than the length of the secondary terminal pins protruding from the lower flange.

The above-mentioned outer frame is formed by the second molding part, the secondary terminal pin protruding from the above-mentioned upper flange protrudes along the side surface of the above-mentioned second molding part and bends downward, the secondary terminal pin protruding from the above-mentioned lower flange protrudes toward the lower surface of the above-mentioned second molding part, and the ends of the above-mentioned secondary terminal pin protruding along the side surface of the above-mentioned second molding part and bending downward and the end of the above-mentioned secondary terminal pin protruding toward the lower surface of the above-mentioned second molding part may be located at the same height.

The outer frame combined with the inner frame is formed by a second forming portion.

The primary terminal pins and the secondary terminal pins protrude toward the outside of the second molded portion.

The plurality of primary terminal pins are spaced apart from each other and arranged in one row, and the plurality of secondary terminal pins are spaced apart from each other and arranged in two rows.

The present invention has the following effects: since one lead wire (copper wire) is connected to one terminal pin, the risk of short circuit can be prevented and the withstand voltage can be stably maintained by ensuring a safe distance between the terminal pins even in the case of thick copper wires.

Furthermore, the present invention has the following effect: since one lead is connected to one terminal pin, a high allowable current can be provided without causing a current bottleneck phenomenon.

Furthermore, the present invention has the following effects: since one lead wire is connected to one terminal pin, automatic winding and automatic connection are possible, thereby realizing fully automated manufacturing.

Furthermore, the present invention has the following effects: it is manufactured into a full molding type by insert injection molding, so that high insulation reliability can be achieved by perfect insulation between the primary coil and the secondary coil, and excellent waterproofness can be obtained by preventing the secondary coil from being exposed to the outside.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an existing transformer that can obtain a variety of different voltages.

2 is a perspective view showing a state before a body is combined with an upper core and a lower core in the transformer according to the embodiment of the present invention.

FIG. 3 is a perspective view showing the lower surface of the transformer according to the embodiment of the present invention.

FIG. 4 is a perspective view showing the interior of the transformer according to the embodiment of the present invention.

FIG. 5 is a cross-sectional view showing a main body according to an embodiment of the present invention.

FIG. 6 is a perspective view showing an inner frame according to an embodiment of the present invention.

FIG. 7 is a perspective view showing a state where a coil is wound around an inner bobbin according to an embodiment of the present invention.

FIG. 8 is a perspective view showing an inner molding skeleton according to an embodiment of the present invention.

FIG. 9 is a perspective view showing an outer side frame according to an embodiment of the present invention.

FIG. 10 is a perspective view showing a state where a coil is wound around an outer bobbin according to an embodiment of the present invention.

FIG. 11 is a three-dimensional view showing a state where an outer frame and an inner molding frame are combined according to an embodiment of the present invention.

FIG. 12 is a perspective view showing a main body according to an embodiment of the present invention.

FIG. 13 is a flow chart showing a transformer manufacturing method according to an embodiment of the present invention.

FIG. 14 is a diagram showing a method of connecting a coil and terminal pins of a transformer according to an embodiment of the present invention.

DETAILED DESCRIPTION

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

2 is a perspective view showing a state before a body is combined with an upper core and a lower core in the transformer according to the embodiment of the present invention.

As shown in FIG. 2 , the transformer 10 includes: a body 100 ; and a core 200 combined with the body 100 .

The body 100 includes a primary coil and a secondary coil inside, and includes a primary terminal pin 130 connected to the primary coil and a secondary terminal pin 170 connected to the secondary coil outside. The body 100 physically and firmly wraps the secondary coil, and achieves electrical insulation from the outside and a waterproof function by integrally forming the primary coil and the secondary coil.

The primary terminal pins 130 are located at one lower part of the body 100, and the secondary terminal pins 170 are located at the other lower part. The primary terminal pins 130 are input terminal pins, and the secondary terminal pins 170 are output terminal pins.

In the embodiment, the primary terminal pin 130 is shaped to protrude downward from the lower surface of one side of the body 100. There are a plurality of primary terminal pins 130, and the plurality of primary terminal pins 130 are arranged in a row in a mutually spaced manner. The secondary terminal pin 170 includes a lower secondary terminal pin 170a and an upper secondary terminal pin 170b.

The lower secondary terminal pin 170a is a shape that protrudes downward from the lower surface of the other side of the body 100, and the upper secondary terminal pin 170 is a shape that protrudes from the upper end of the other side of the body 100 toward the outside and bends downward, and a portion of the bend protrudes toward the lower part of the body 100. There are multiple upper secondary terminal pins 170b and lower secondary terminal pins 170a, and the multiple upper secondary terminal pins 170b and lower secondary terminal pins 170a are arranged in two rows in a mutually spaced manner. That is, the primary terminal pins 130 are configured in one row, and the secondary terminal pins 170 are configured in two rows. The two rows of the secondary terminal pins 170 are configured to achieve separated winding for multiple leads (copper wires) and ensure the insulation distance (safety distance) between the terminal pins. The lead wire is an electric wire led out for connecting the primary coil and the secondary coil. Copper wire can be used for the lead wire.

The terminal pins need to be separated from each other and maintained insulated. This can improve the withstand voltage characteristics between the wound coils and reduce the mutual capacitance with adjacent terminal pins, thereby minimizing the noise affecting other terminal pins and stabilizing the supply voltage.

If the terminal pins 170 are arranged in two rows, a plurality of terminal pins can be included without increasing the size of the transformer, and only one lead can be connected to one terminal pin.

The core 200 includes an upper core 200a and a lower core 200b. The upper core 200a is combined with the upper part of the body 100, and the lower core 200b is combined with the lower part of the body 100. The upper core 200a and the lower core 200b form a magnetic circuit around the coil. The upper core 200a and the lower core 200b are made of magnetic material. The magnetic material is formed of a ferromagnetic substance that can obtain a strong magnetic flux, and a ferrite core with low loss under high frequency conditions can be used. As an example, the magnetic material can use a manganese-zinc (Mn-Zn) ferrite core.

The upper core 200a and the lower core 200b include a flat plate portion a, two side convex portions b and a central convex portion c. The two side convex portions b are formed by vertically protruding from both sides of the flat plate portion a, and the central convex portion c is formed by vertically protruding between the two side convex portions b. The cross-sections of the upper core 200a and the lower core 200b form an E shape.

The flat plate portion a of the upper core 200a and the lower core 200b is tightly attached to the upper or lower surface of the core coupling portion 101, the two side convex portions b are tightly attached to the two side surfaces in the width direction of the core coupling portion 101, and the center convex portion c is connected to the main body 100 by being inserted into the core coupling hole 112.

FIG. 3 is a perspective view showing the lower surface of the transformer according to the embodiment of the present invention.

As shown in Fig. 3, the primary terminal pin 130 protrudes downward from the lower surface of one side of the body 100, and the secondary terminal pin 170 protrudes downward from the lower surface of the other side of the body 100 and a position separated from the lower surface of the other side of the body. Among the secondary terminal pins 170, the lower secondary terminal pins 170a and the upper secondary terminal pins 170b are arranged in two rows.

In order to selectively obtain a variety of different output voltages for an input voltage, a variety of winding ratios of the primary coil and the secondary coil, and thicknesses of the primary coil and the secondary coil may be selected.

To this end, more than two primary coils and more than eight secondary coils may be wound. Furthermore, in order to connect each terminal pin to the end lead of one coil, the primary terminal pins 130 may be more than four, the lower secondary terminal pins 170a may be more than eight, and the upper secondary terminal pins 170b may be more than eight. Furthermore, the number of the lower secondary terminal pins 170a may be the same as the number of the upper secondary terminal pins 170b.

In the embodiment, since there are two primary coils and eight secondary coils, the function of four transformers can be realized by one transformer. To this end, there are two primary coils, eight secondary coils, five primary terminal pins 130, and 16 secondary terminal pins 170. There are eight secondary terminal pins 170 at the top and bottom, respectively, thereby ensuring a safe distance between the terminal pins and realizing separate winding of multiple leads.

The primary terminal pins 130 in one row and the secondary terminal pins 170 in two rows may be inserted and coupled to substrate coupling holes formed on the substrate and connected to the circuits of the substrate.

FIG. 4 is a perspective view showing the inside of the transformer according to the embodiment of the present invention.

As shown in FIG4 , the body 100 includes a primary coil 140 and a secondary coil 180 inside. The body 100 is made of an insulating material, which is used to insulate the secondary coil 180 from the outside and protect the secondary coil 180 in conditions such as moisture resistance. The secondary coil 180 is arranged around the outer circumference of the primary coil 140, and the secondary coil 180 and the primary coil 140 are insulated by the first molded portion 150.

An end lead of the primary coil 140 is connected to each primary terminal pin 130 , and an end lead of the secondary coil 180 is connected to each secondary terminal pin 170 .

FIG. 5 is a cross-sectional view showing a main body according to an embodiment of the present invention.

As shown in FIG. 5 , the body 100 includes an inner frame 120 , a primary coil 140 , primary terminal pins 130 , an outer frame 160 , a secondary coil 180 and secondary terminal pins 170 .

The primary coil 140 is wound around the inner frame 120 . The primary terminal pin 130 is formed to protrude from one side of the inner frame 120 and is connected to an end lead of the primary coil 140 .

The inner frame 120 is inserted into the center of the outer frame 160. The secondary coil 180 is wound on the outer frame 160. The secondary terminal pin 170 is formed to protrude in a vertically separated manner on the other side of the outer frame 160 and is connected to the end lead of the secondary coil 180. The other side of the outer frame 160 is opposite to the direction in which the primary coil 140 protrudes from the inner frame 120.

The primary terminal pin 130 protruding from one side of the inner frame 120 is bent toward the lower portion and protrudes downward from the lower surface of the body 100 .

The lower secondary terminal pin 170a protruding from the lower part of the other side of the outer frame 160 protrudes downward from the lower surface of the main body 100, and the upper secondary terminal pin 170b protruding from the upper part of the other side of the outer frame 160 is led out from the upper part of the other side of the main body 100 toward the outside and bent downward.

The inner frame 120 may be formed by the first molding part 150. The first molding part 150 is made of an insulating material and is used to insulate the primary coil 140 from the secondary coil 180 and protect the primary coil 140 in moisture resistance and other conditions. A portion of the primary terminal pin 130 to which the primary coil 140 is connected to the end lead of the primary coil is located inside the first molding part 150, and the remaining portion of the primary terminal pin 130 is located outside the first molding part 150.

The outer frame 160 combined with the inner frame 120 is formed by the second molding part 190. The second molding part 190 is made of an insulating material, and is used to insulate the secondary coil 180 from the outside and protect the secondary coil 180 in conditions such as moisture resistance. The primary terminal pins 130 and the secondary terminal pins 170 are led out toward the outside of the second molding part 190. That is, a part of the primary terminal pins 130 located outside the first molding part 150 is located inside the second molding part 190, and the remaining part protrudes to the outside of the second molding part 190. In addition, a part of the secondary terminal pins 170 is located inside the second molding part 190, and the remaining part protrudes to the outside of the second molding part 190. The outer frame 160 combined with the inner frame 120 is molded into the body 100 by the second molding part 190.

FIG. 6 is a perspective view showing an inner frame according to an embodiment of the present invention.

As shown in FIG. 6 , the inner frame 120 includes: a primary winding portion 121 wound with a primary coil; and a core coupling hole 122 penetrating the center of the primary winding portion 121 in the up-down direction. The inner frame 120 is provided with an upper flange 123 and a lower flange 124, which are formed by expanding along the outer diameter direction at the upper and lower ends of the primary winding portion 121. The lower flange 124 is also formed with an extension flange 125 on one side, and a plurality of primary terminal pins 130 are provided on the extension flange 125. The plurality of primary terminal pins 130 can be fixed in the embedding holes formed in the extension flange 125 at a predetermined interval, and can also be fixed as a whole with the extension flange 125 in the process of forming the inner frame 120. If the primary terminal pins 130 are fixed as a whole with the inner frame 120 in the process of forming the inner frame 120, the primary terminal pins 130 can be firmly fixed to the inner frame 120.

The inner frame 120 is formed with a concave groove 126 for injecting molding material into both ends of the upper flange 123. When the inner frame 120 and the outer frame 160 are combined, the concave groove 126 can be a hole for injecting molding material for insert injection between the inner frame 120 and the outer frame 160.

In the embodiment, the inner molded frame 110 is manufactured by combining the first molded portion 150 with the inner frame 120, and the inner molded frame 110 is combined with the outer frame 160. However, in the process of combining the outer frame 160 with the inner frame 120 and combining the second molded portion 190 with the outer frame 160, the first molded portion 150 may be combined between the inner frame 120 and the outer frame 160 by injecting a molding substance between the inner frame 120 and the outer frame 160. In this case, the concave groove 126 needs to be formed in the inner frame 120 so that the molding substance can be injected between the inner frame 120 and the outer frame 160.

The inner frame 120 is made of insulating resin and can be formed by injection molding. Preferably, the inner frame 120 can be made of a material with high temperature resistance and high voltage resistance. As an example, the inner frame 120 can ensure an insulation performance of more than 20kv/mm by using polybutylene terephthalate (PBT) material.

FIG. 7 is a perspective view showing a state where a coil is wound around an inner bobbin according to an embodiment of the present invention.

As shown in Fig. 7, the primary coil 140 is wound on the primary winding portion 121 of the inner frame 120. In the embodiment, there are more than two primary coils 140 wound on the primary winding portion 121. The end lead 141 of the primary coil 140 wound on the primary winding portion 121 is wound on the primary terminal pin 130 and connected by welding P method.

There are more than two primary coils 140, which are wound multiple times on the primary winding part 121. The upper flange 123 and the lower flange 124 support the primary coil 140 wound on the primary winding part 121 by maximally ensuring the winding space of the primary winding part 121, so that the primary coil 140 is stably wound on the primary winding part 121.

FIG. 8 is a perspective view showing an inner molding skeleton according to an embodiment of the present invention.

As shown in Fig. 8, the first molding part 150 is combined with the inner frame 120 and the primary coil 140 to form the inner molding frame 110. The first molding part 150 is formed by combining the molding material with the inner frame 120 and the primary coil 140 and the portion where the end lead 141 of the primary coil 140 is connected by insert injection molding with the primary terminal pin 130 leading outward.

Before combining the first molded part 150 with the inner frame 120, the primary terminal pins 130 are bent to protrude toward the lower portion of the first molded part 150. The first molded part 150 uniformly surrounds the inner frame 120 with a prescribed thickness, and thus the primary coil 140 cannot be exposed to the outside.

FIG. 9 is a perspective view showing an outer side frame according to an embodiment of the present invention.

As shown in FIG9 , the outer frame 160 includes: a secondary winding portion 161, on which a secondary coil 180 is wound; and a frame coupling hole 162, which passes through the center of the secondary winding portion 161 in the up-down direction. The inner frame 120 or the inner molding frame 110 is coupled to the frame coupling hole 162, and the inner molding frame 110 couples the first molding portion 150 to the inner frame 120. In the embodiment, the frame coupling hole 162 is coupled to the inner molding frame 110.

The outer frame 160 is provided with an upper flange 163 and a lower flange 164, which are expanded along the outer diameter direction at the upper end and the lower end of the secondary winding part 161. The secondary winding part 161 is formed between the upper flange 163 and the lower flange 164, and the secondary coil 180 is wound on the secondary winding part 161.

The secondary winding portion 161 improves withstand voltage by forming the portion connected to the upper flange 163 and the lower flange 164 into an arc shape. Withstand voltage refers to the degree of withstanding without bursting when a high voltage is applied. The formation of the arc-shaped portion has the following effects, that is, after insert injection molding, the strength can be enhanced by eliminating internal pores and the withstand voltage can be improved.

The outer frame 160 has the upper flange 163 and the lower flange 164 formed in a symmetrical shape, thereby achieving a balance of left and right forces. This method can minimize the problem of damage to the outer frame 160 during the process of winding the secondary coil 180 around the outer frame 160.

Locking grooves 165 are formed in the upper flange 163 and the lower flange 164 of the outer frame 160 .

The locking groove 165 is a portion where the end lead of the secondary coil 180 wound on the secondary winding portion 161 is locked and supported before being connected to the secondary terminal pin 170. The locking groove 165 is formed concavely in the upper flange 163 and the lower flange 164 along the rear end direction and is formed in a plurality of forms in a state of opening in the vertical direction.

The secondary terminal pins 170 protrude from the upper flange 163 and the lower flange 164 corresponding to both sides of the locking groove 165 .

The secondary terminal pins 170 protruding from the outer frame are formed in pairs symmetrically in the vertical direction, and each pair of two secondary terminal pins 170 in the vertical direction is connected to an end lead of a secondary coil 180. In the embodiment, there are 16 secondary terminal pins 170.

The length of the upper secondary terminal pin 170b protruding from the upper flange 163 is longer than the length of the lower secondary terminal pin 170a protruding from the lower flange 164. The length of the upper secondary terminal pin 170b is longer than the length of the lower secondary terminal pin 170a, so that the upper secondary terminal pin 170b and the lower secondary terminal pin 170a are located at the same height by bending the upper secondary terminal pin 170b.

In the embodiment, the ends of the upper secondary terminal pins 170b protruding to the outside of the second molded portion 190 and the lower secondary terminal pins 170a protruding to the outside of the second molded portion 190 and bent downward are located at the same height. Thus, the upper secondary terminal pins 170b and the lower secondary terminal pins 170a arranged in two rows can be easily embedded and combined in the substrate.

A plurality of secondary terminal pins 170 may also be fixed in the embedding holes formed at predetermined intervals in the upper flange 163 and the lower flange 164 corresponding to both sides of the locking groove 165, and the upper flange 163 and the lower flange 164 may also be fixed as one body during the process of forming the outer frame 160. During the process of forming the outer frame 160, if the secondary terminal pins 170 are fixed as one body with the outer frame 160, the secondary terminal pins 170 may be firmly fixed to the outer frame 160.

The outer frame 160 is the same as the inner frame 120 and can be made of a material that is resistant to high temperatures and high voltages.

FIG. 10 is a perspective view showing a state where a coil is wound around an outer bobbin according to an embodiment of the present invention.

As shown in Fig. 10, the secondary coil 180 is wound around the secondary winding portion 161 of the outer frame 160. The end lead 171 of the secondary coil 180 wound around the secondary winding portion 161 is wound around the secondary terminal pin 170b and connected by welding.

The secondary coil 180 is wound multiple times on the secondary winding part 161. The upper flange 163 and the lower flange 164 can support the secondary coil 180 wound on the secondary winding part 161 by maximally ensuring the winding space of the secondary winding part 161, so that the secondary coil 180 is stably wound on the secondary winding part 161.

In order to selectively obtain a variety of different output voltages for an input voltage, there may be various types of winding ratios of the primary coil 140 and the secondary coils 180 and thicknesses of the secondary coils 180. In an embodiment, the number of secondary coils 180 wound on the secondary winding portion 161 is more than 8.

FIG. 11 is a three-dimensional view showing a state where an outer frame and an inner molding frame are combined according to an embodiment of the present invention.

As shown in Fig. 11, the frame coupling hole 162 of the outer frame 160 is coupled to the inner molding frame 110. The inner molding frame 110 is coupled to the frame coupling hole 162 of the outer frame 160 to position the primary terminal pins 130 and the secondary terminal pins 170 in opposite directions.

FIG. 12 is a perspective view showing a main body according to an embodiment of the present invention.

As shown in FIG. 12 , if the outer frame 160 combined with the inner molding frame 110 is put into a mold and insert injection molding is performed, the body 100 in which the second molding portion 190 is combined with the inner frame 120 and the outer frame 160 is formed.

The second molded portion 190 surrounds the secondary coil 180 and surrounds the boundary between the outer frame 160 and the inner molded frame 110 to form the inner molded frame 110 and the outer frame 160 as one body.

The body 100 forms both sides into molded flanges and forms a core coupling portion 101 therebetween. The molded flange is a portion formed by the second molded portion 190 surrounding the upper flange 163 and the lower flange 164 of the outer frame 160 with a specified thickness. The core coupling portion 101 is equivalent to a portion forming a height difference between the molded flanges on both sides. A core coupling hole 122 is formed in the center of the core coupling portion 101 and passes through in the up and down directions. The core coupling portion 101 and the core coupling hole 122 are combined with the upper core 200a and the lower core 200b. The width and length of the core coupling portion 101 are pre-designed in consideration of the sizes of the upper core 200a and the lower core 200b combined with the core coupling portion 101.

The primary terminal pin 130 protrudes downward from the lower surface of one side of the body 100, and the lower secondary terminal pin 170a protrudes downward from the lower surface of the other side of the body 100. In addition, the upper secondary terminal pin 170b protrudes outward from the upper portion of the other side of the body 100. The upper secondary terminal pin 170b protruding outward from the upper portion of the other side of the body is bent downward and spaced apart from the lower secondary terminal pin 170a and arranged side by side.

FIG. 13 is a flow chart showing a transformer manufacturing method according to an embodiment of the present invention.

As shown in Figure 13, the transformer manufacturing method includes: the step of preparing the inner frame 120; the step of winding the primary coil 140 onto the primary winding part 121 of the inner frame 120; and the step of combining the first molding part 150 with the inner frame 120, thereby manufacturing the inner molding frame 110.

Furthermore, the transformer manufacturing method includes: a step of preparing an outer frame 160; a step of winding a secondary coil on the outer frame 160; a step of combining the outer frame 160 with the inner molding frame 110; and a step of combining the inner frame 120 and the outer frame 160 with the second molding portion 190, thereby manufacturing the main body 100.

In addition, the transformer manufacturing method includes: a step of arranging the upper secondary terminal pin 170b extending toward the upper part of the other side of the main body 100 in two rows side by side with the lower secondary terminal pin 170a; and a step of combining the core coupling portion 101 of the main body 100 with the upper core 200a and the lower core 200b, thereby finally manufacturing a transformer.

In the step of preparing the inner skeleton 120 , the inner skeleton 120 is formed by injection molding, and the inner skeleton 120 has a core coupling hole 122 , a primary winding portion 121 , an upper flange, a lower flange 124 and an extended flange 125 , so that a plurality of primary terminal pins 130 protrude from the extended flange 125 .

In the step of winding the primary coil 140 around the primary winding portion 121 of the inner frame 120, a plurality of primary coils 140 are wound around the primary winding portion 121, and the end leads 141 of the primary coils 140 are wound around the primary terminal pins 130 and fixed by welding. In this case, each primary terminal pin 130 is connected to one end lead 141, so that the insulation distance between the primary terminal pins 130 can be ensured.

In the step of combining the inner frame 120 with the first molded portion 150 , the portion connected to the inner frame 120 , the primary coil 140 , and the end lead 141 of the primary coil 140 is combined with the first molded portion 150 by insert injection molding in which the primary terminal pin 130 is led outward.

In the step of preparing the outer skeleton 160, the outer skeleton 160 is formed by injection molding, and the outer skeleton 160 has a skeleton combining hole 162, a secondary winding portion 161, an upper flange 163, a lower flange 164 and a recessed groove 126, and the secondary terminal pin 170 protrudes from the upper flange 163 and the lower flange 164.

In the step of winding the secondary coil 180 around the outer frame 160, a plurality of secondary coils 180 are wound around the secondary winding portion 161, and the end leads 171 of the secondary coils 180 are wound around the secondary terminal pins 170 and fixed by welding. In this case, each secondary terminal pin 170 is connected to one end lead 171, so that the insulation distance between the secondary terminal pins 170 can be ensured. In addition, the two end leads 171 of one secondary coil are respectively connected to the secondary terminal pins 170 arranged in the up and down directions.

In the step of combining the outer frame 160 with the inner molding frame 110 , the frame combining holes 162 of the outer frame 160 are combined with the inner molding frame 110 .

In the step of combining the second molded part 190 with the inner frame 120 and the outer frame 160, the portion connected to the inner frame 120 and the outer frame 160 and the secondary coil 180 and the end lead 171 of the secondary coil is combined with the second molded part 190 by an insert injection molding method in which the primary terminal pin 130 and the secondary terminal pin 170 are led outward.

In the step of bending the upper secondary terminal pin 170b extending toward the upper part of the other side of the body 100 to arrange it in two rows side by side with the lower secondary terminal pin 170a, the upper secondary terminal pin 170b is separated from the lower secondary terminal pin 170a to ensure a safe distance between the secondary terminal pins 170.

In the step of combining the core combining part 101 of the body 100 with the upper core 200a and the lower core 200b, the upper core 200a and the lower core 200b combined with the core combining part 101 of the body 100 may be fixed in a combined state by bonding the surfaces in contact with the body 100 with epoxy resin or bonding the surfaces in contact with the upper core 200a and the lower core 200b with epoxy resin. Epoxy resin has the effect of improving waterproofness and minimizing fragments when broken and making it easy to confirm cracks.

The thickness of the inner frame 120, the thickness of the first molded part 150 combined with the inner frame 120, the thickness of the outer frame 160, and the thickness of the second molded part 190 combined with the outer frame 160 can all be within the range of 0.5mm to 0.55mm. The main body 100 is a structure that completely shields the primary coil 140 and the secondary coil 180.

In the embodiment, the diameter of the primary terminal pin 130 and the secondary terminal pin 170 is 1.5 mm, the interval between the terminal pins is in the range of 4 mm to 5 mm, and the interval between the upper secondary terminal pin 170b and the lower secondary terminal pin 170a is 3 mm. In such a small transformer, if each terminal pin is connected to a lead, a short circuit can be prevented and the withstand voltage characteristics can be improved by ensuring a safe distance between the terminal pins.

Furthermore, in the embodiment, the connection portion between the primary terminal pin 130 and the end lead 141 of the primary coil is located inside the first molded portion 150, and the connection portion between the secondary terminal pin 170 and the end lead 171 of the secondary coil is located inside the second molded portion 190, so that poor contact caused by external force does not occur after connection.

FIG. 14 is a diagram showing a method of connecting a coil and terminal pins of a transformer according to an embodiment of the present invention.

As shown in FIG14 , the two end leads of the first primary coil wound on the inner frame are connected to primary terminal pin No. 1 and primary terminal pin No. 2 respectively, and the two end leads of the second primary coil can be connected to primary terminal pin No. 4 and primary terminal pin No. 5 respectively.

In addition, the two ends of the first secondary coil wound on the outer frame are respectively connected to secondary terminal pin No. 13 and secondary terminal pin No. 7, the two ends of the second secondary coil are respectively connected to secondary terminal pin No. 12 and secondary terminal pin No. 6, the two ends of the third secondary coil are respectively connected to terminal pin No. 11 and terminal pin No. 8, the two ends of the fourth secondary coil are respectively connected to secondary terminal pin No. 10 and secondary terminal pin No. 9, the two ends of the fifth secondary coil are respectively connected to secondary terminal pin No. 21 and secondary terminal pin No. 15, the two ends of the sixth secondary coil are respectively connected to secondary terminal pin No. 20 and secondary terminal pin No. 14, the two ends of the seventh secondary coil are respectively connected to secondary terminal pin No. 19 and secondary terminal pin No. 16, and the two ends of the eighth secondary coil can be connected to secondary terminal pin No. 18 and secondary terminal pin No. 17, respectively.

The 13th secondary terminal pin and the 21st secondary terminal pin are embedded and coupled to the substrate coupling hole formed in the substrate and connected to each other, and can be connected to the output side circuit of the substrate.

Table 1 below shows an example of FIG. 14 in which two secondary terminal pins are connected to one coil.

Table 1

As shown in FIG14 , the winding ratio of the primary coil to the secondary coil can be adjusted by selectively connecting a circuit to the secondary terminal pin, thereby obtaining a variety of different output voltages, thereby having a higher allowable current.

Since the transformer of the present invention has one lead wire (copper wire) connected to one terminal pin, it is possible to stably maintain the withstand voltage by ensuring a safe distance between the terminal pins and preventing the risk of short circuit.

Furthermore, since one terminal pin of the transformer of the present invention is connected with a lead wire, the current bottleneck phenomenon can be prevented from occurring.

Furthermore, since one terminal pin of the transformer of the present invention is connected to a lead wire, automatic winding and automatic connection can be performed to realize automated manufacturing.

Furthermore, since the transformer of the present invention can divide and wind a plurality of lead wires in the vertical direction, the insulation distance between the terminal pins can be ensured even in a small transformer.

Furthermore, since the present invention realizes perfect insulation between the primary coil and the secondary coil by insert injection molding, it has higher insulation reliability, and obtains excellent waterproofness by preventing the secondary coil from being exposed to the outside.

The transformer can be installed in a television (TV), a display, a light emitting diode (LED) driving power supply device, a computer power supply, etc. to achieve a stable power supply.

In the embodiment, although the case where the plurality of secondary terminal pins are spaced apart from each other and arranged in two rows is described as an example, the plurality of secondary terminal pins may be formed in three or more rows depending on design conditions.

In the present invention, preferred embodiments are disclosed in the drawings and the specification. Although specific terms are used, such terms are only used to illustrate the present invention and are not used to limit the meaning or the scope of the present invention as described in the scope of protection of the invention. Therefore, it should be understood that a person skilled in the art of the present invention can make various modifications or derive other equivalent embodiments. Therefore, the true technical rights scope of the present invention should be determined based on the technical ideas of the scope of protection of the invention.

Claims (14)

1. A transformer is characterized in that,

Comprising the following steps:

A body; and

A core combined with the body,

The body includes:

An inner skeleton;

a primary coil wound around the inner bobbin;

A plurality of primary terminal pins formed on one side of the inner frame and connected to the end leads of the primary coil;

An outer skeleton coupled to the inner skeleton;

A plurality of secondary coils wound around the outer frame; and

A plurality of secondary terminal pins formed on the other side of the outer frame in a direction opposite to the direction in which the primary terminal pins protrude from the inner frame, and connected to the end leads of the secondary coil,

The plurality of secondary terminal pins are formed at the other side of the outer frame in a vertically spaced manner,

Each of the secondary terminal pins is connected to an end lead of the secondary coil,

The secondary terminal pin includes:

a lower secondary terminal pin bent toward a lower portion and protruding from a lower portion of the body toward the lower portion; and

And upper secondary terminal pins formed on the other side of the outer frame at upper portions of the lower secondary terminal pins and bent downward, and arranged in parallel with the lower secondary terminal pins while being spaced apart from the lower secondary terminal pins.

2. The transformer of claim 1, wherein the primary terminal pin is bent toward a lower portion and protrudes from a lower portion of the body toward the lower portion.

3. The transformer of claim 1, wherein the number of lower secondary terminal pins is the same as the number of upper secondary terminal pins.

4. The transformer of claim 1, wherein the upper secondary terminal pin is longer than the lower secondary terminal pin, and wherein ends of the upper secondary terminal pin and the lower secondary terminal pin are at the same height.

5. The transformer according to claim 1, wherein the transformer comprises a transformer,

The plurality of secondary terminal pins formed on the outer side frame are formed in pairs along the up-down direction and are symmetrical to each other,

One of the secondary coils is connected to each of two secondary terminal pins paired in the up-down direction.

6. The transformer according to claim 1, wherein the inner frame is molded by a first molding portion.

7. The transformer according to claim 6, wherein a part of the primary terminal pin of the primary coil connected to the end lead of the primary coil is located inside the first molding portion, and the remaining part of the primary terminal pin protrudes outside the first molding portion.

8. The transformer according to claim 1, wherein the outer bobbin comprises:

a secondary winding part around which a secondary coil is wound;

An upper flange and a lower flange formed at both sides of the secondary winding portion, respectively, for forming a winding space therebetween; and

And a plurality of locking grooves formed on the upper flange and the lower flange for locking and supporting the end lead of the secondary coil wound around the secondary winding part before being connected to the secondary terminal pin.

9. The transformer of claim 8, wherein the secondary terminal pins are protruded from the upper flange and the lower flange corresponding to both sides of the locking groove.

10. The transformer of claim 8, wherein the length of the secondary terminal pin protruding from the upper flange is longer than the length of the secondary terminal pin protruding from the lower flange.

11. The transformer according to claim 10, wherein the outer bobbin is formed by a second forming portion,

Secondary terminal pins protruding from the upper flange protrude along a side surface of the second molding part and are bent toward a lower part,

The secondary terminal pins protruding from the lower flange protrude toward the lower face of the second molding part,

The secondary terminal pin protruding along the side surface of the second molding part and bent toward the lower part and the end of the secondary terminal pin protruding toward the lower surface of the second molding part are located at the same height.

12. The transformer according to claim 1, wherein the outer bobbin combined with the inner bobbin is formed by a second forming part.

13. The transformer of claim 12, wherein the primary terminal pin and the secondary terminal pin protrude toward the outside of the second molding portion.

14. The transformer of claim 1, wherein said plurality of primary terminal pins are spaced apart from each other and arranged in a row, and said plurality of secondary terminal pins are spaced apart from each other and arranged in two rows.