RESONANT HIGH CURRENT DENSITY TRANSFORMER

Abstract

A resonant high current density transformer including two cores that are abut against each other with their first and second side posts on two sides thereof. A first bobbin envelops the first side posts on the same side of the two cores. A side plate is provided on either end of the first bobbin. The space between the two side plates is divided into two coil slots with a spacer, and at least a wire is wound in each coil slot to form a primary winding. A further second bobbin envelops the second side posts on the same side of the two cores. The outer periphery of the second bobbin is divided into two winding regions by another spacer, and a metal plate envelops each of the winding regions to form a secondary winding. A bobbin mount is disposed at the external flank of the second bobbin with a barrier plate at a side thereof for separating the first and the second bobbins. An insulating separating cover is provided on a side of the first bobbin closer to the bobbin mount, and the two ends of the separating cover cover the top and bottom sides of the first bobbin, respectively.

Claims

1. A resonant high current density transformer comprising: two cores, each including first and second side posts extending in the same direction from two sides thereof, wherein the two cores abut against each other with the two first side posts facing each other and the two second side posts facing each other; a first bobbin provided with a penetrating first through-hole that envelops the first side posts on the same side of the two cores, wherein a side plate is provided on the outer periphery of either end of the first through-hole, and a spacer is provided on the first bobbin between the two side plates on the outer periphery of the first through-hole, and two coil slots are formed on the two sides of the spacer, respectively; a primary winding formed by winding wires around the two coil slots of the first bobbin; a second bobbin provided with a penetrating second through-hole that envelops the second side posts on the same side of the two cores, wherein the second bobbin is provided with a spacer on the mid-section of the outer periphery of the second through-hole, and two winding regions and are formed on the two sides of the spacer, respectively; two metal plates bent to envelop the outer peripheries of the winding regions and of the second bobbin to form a secondary winding; a bobbin mount disposed at the external flank of the second bobbin, the bobbin mount including a base provided with a barrier plate on a side closer to the first bobbin, wherein the barrier plate is used for separating the first and second bobbins; and an insulating U-shape separating cover provided on a side of the first bobbin closer to the bobbin mount, wherein the two ends of the separating cover the top and bottom sides of the first bobbin, respectively.

2. The resonant high current density transformer of claim 1, wherein a lateral fastening groove is provided on a side of each side plate closer to the coil slot, whereas a lateral flap corresponding to each lateral fastening groove is provided on each of two lateral edges of the separating cover, and the separating cover is secured at the outer side of the coil slots of the first bobbin by inserting each lateral flap into the corresponding lateral fastening groove.

3. The resonant high current density transformer of claim 1, wherein a first engaging tenon and a first engaging slot are provided on a side of the first bobbin closer to the bobbin mount, whereas a corresponding second engaging slot and a corresponding second engaging tenon are provided on a side of the bobbin mount closer to the first bobbin, the bobbin mount and the first bobbin are joined together by inserting the first engaging tenon into the second engaging slot and the second engaging tenon into the first engaging slot.

4. The resonant high current density transformer of claim 1, wherein the first bobbin is provided with a first side retainer on each of the two side plates, and a first positioning recess is provided on a side of each first side retainer facing the first through-hole, whereas the base is provided with a second side retainer at each of the two ends thereof on a side away from the barrier plate, and a second positioning recess is provided on a side of each second side retainer facing the barrier plate, and the first and the second positioning recesses abut against two lateral edges of the two cores, respectively.

5. The resonant high current density transformer of claim 4, wherein a plurality of terminals are provided on the first and the second side retainers.

6. The resonant high current density transformer of claim 4, wherein the base is provided with a middle slot between the barrier plate and the second side retainers, and a side slot is provided on each of the two sides of the middle slot, whereas each of the metal plates include a lateral end and a middle end, and the middle ends of the metal plates both pass through the middle slot, while the lateral ends of the metal plates at different winding regions pass through different lateral slots.

7. The resonant high current density transformer of claim 1, wherein a plurality of gaps are provided on the spacer of the first bobbin.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is an exploded view of the structure of the present invention.

[0026] FIG. 2 is an exterior view of the overall assembly of the present invention.

[0027] FIG. 3 is a cross-sectional view of the assembly of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Referring to FIGS. 1 to 3, it can be understood that the structure of the present invention mainly includes: two cores 1, a first bobbin 2, a bobbin mount 3, a second bobbin 4, a separating cover 5, a metal plate 6 and a primary winding 7; wherein first and second side posts 11 and 12 extending in the same direction from the two sides of each of the cores 1. When the two cores 2 abut against each other with the two first side posts 11 facing each other and the two second side posts 12 facing each other, a magnetic loop is formed.

[0029] The first bobbin 2 is provided with a penetrating first through-hole 21, which envelops the first side posts 11 on the same side of the two cores 1 at their outer peripheries. A side plate 22 is provided on the outer periphery of either end of the first through-hole 21. A spacer 23 is provided between the two side plates 22. Two coil slots 231 are formed on the two sides of the spacer 23, respectively. A plurality of gaps 232 are provided on the spacer 23. A lateral fastening groove 221 is provided on the side of each side plate 22 closer to the coil slot 231, whereas a first side retainer 24 is provided on the side of each side plate 22 away from the coil slot 231. A first engaging tenon 251 (e.g. a dovetail tenon) and a first engaging slot 25 (e.g. a dovetail slot) are provided on a side of the first bobbin 2 away from the first side retainers 24. A plurality of terminals 242 are provided on the two first side retainers 24. A first positioning recess 241 is provided on the side of each first side retainer 24 facing the first through-hole 21; in one possible embodiment, the first positioning recess 241 has an edge shape conforming to the side of the core 1 closer to the first side post 11, such that the first positioning recess 241 conforms to and abuts against the side edge of the core 1 closer to the first side post 11 to facilitate positioning.

[0030] The primary winding 7 is formed by winding wires around each coil slot 231 of the first bobbin 2, and the gaps 232 allow wires to pass through. The wire ends of the primary winding 7 are connected to the terminals 242.

[0031] The second bobbin 4 is provided with a penetrating second through-hole 41, which envelops the second side posts 12 on the same side of the two cores 1 at their outer peripheries. The second bobbin 4 is provided with a spacer 42 on the mid-section of the outer periphery of the second through-hole 41. Winding regions 43 and 431 are formed on the two sides of the spacer 42, respectively.

[0032] The bobbin mount 3 is disposed at the external flank of the second bobbin 4. The bobbin mount 3 includes a base 31. A barrier plate 34 is provided on a side of the base 31 closer to the first bobbin 2. The barrier plate 34 is used for separating the first and second bobbins 2 and 4. A second engaging slot 33 (e.g. a dovetail slot) and a second engaging tenon 331 (e.g. a dovetail tenon), corresponding to the first engaging tenon 251 and the first engaging slot 25, respectively, are provided on a side of the bobbin mount 3 closer to the first bobbin 2. By inserting the first engaging tenon 251 into the second engaging slot 33, and the second engaging tenon 331 into the first engaging slot 25, the bobbin mount 3 and the first bobbin 2 can be joined together.

[0033] A second side retainer 32 is provided on both ends of the side of the base 31 away from the barrier plate 34. A plurality of terminals 322 are provided on each second side retainer 32. The base 31 is provided with a middle slot 311 between the barrier plate 34 and the second side retainers 32. A side slot 312 and a side slot 313 are provided on the two sides of the middle slot 311. A second positioning recess 321 is provided on the side of each second side retainer 32 facing the barrier plate 34. In one possible embodiment, the second positioning recess 321 has an edge shape conforming to the side of the core 1 closer to the second side post 12, such that the second positioning recess 321 conforms to and abuts against the side edge of the core 1 closer to the second side post 12 to facilitate positioning.

[0034] Two metal plates 6 and 60 are bent to envelop the outer peripheries of the winding regions 43 and 431 of the second bobbin 4, thereby forming a secondary winding. The metal plates 6 and 60 include lateral ends 61 and 601, respectively, and middle ends 62 and 602, respectively. The two metal plates 6 and 60 envelop the outer peripheries of the winding regions 43 and 431 of the second bobbin 4 in the opposite directions, such that the middle ends 62 and 602 of the metal plates 6 and 60 both pass through the middle slot 311; the lateral end 61 of the metal plate 6 passes through the lateral slot 312; and the lateral end 601 of the metal plate 60 passes through the lateral slot 313.

[0035] In one possible embodiment, the lateral ends 61 and 601 extend downwards from lateral edges of the metal plates 6 and 60, respectively, while the middle ends 62 and 602 bend and extend at the bottom middle portions of the metal plates 6 and 60. As a result, the distances between the middle ends 62 and 602 (the middle slots 311) and the two lateral ends 61 and 601 (the two lateral slots 312) can be reduced.

[0036] The separating cover 5 is a U-shape insulating plate provided on the side of the first bobbin 2 closer to the bobbin mount 3. The two ends of the separating cover 5 cover the top and bottom sides of the first bobbin 2. A lateral flap 51 corresponding to each lateral fastening groove 221 is provided on each lateral edge of the separating cover 5. By inserting each lateral flap 51 into the corresponding lateral fastening groove 221, the separating cover 5 can be secured at the outer side of the coil slots 231 of the first bobbin 2.

[0037] With the above structure and design, the present invention achieves at least the following technical effects:

[0038] 1. Using the metal plates 6 and 60 in place of ordinary wires as the secondary winding, the overall current output capability is raised, and the size of the secondary winding (transformer) is effectively reduced.

[0039] 2. By fitting the metal plates 6 and 60 onto the two winding regions 43 and 431 of the second bobbin 4, assembly is easier than the traditional coil winding method, and processing efficiency is greatly increased.

[0040] 3. By disposing the primary winding 7 and the metal plates 6 and 60 (secondary winding) on the first and second bobbins 2 and 4, respectively, manufacturing of them can be performed in parallel simultaneously, and then the two are fastened together using corresponding engaging slots and tenons, and further assembled with other parts to form a complete transformer structure. This increases production speed and efficiency, while maintaining stable electrical characteristics of the transformer.

[0041] 4. With the separating cover fencing off the primary and secondary, as well as the primary and the cores, the insulation strength and the creepage distance are increased, thus satisfying the more strict safety requirements specified in medical fields and the like.

[0042] In view of this, the resonant high current density transformer of present invention reduces the size of the transformer, increases power density and simplifies assembly process, and is thus submitted to be novel and non-obvious and a patent application is hereby filed in accordance with the patent law. It should be noted that the descriptions given above are merely descriptions of preferred embodiments of the present invention, various changes, modifications, variations or equivalents can be made to the invention without departing from the scope or spirit of the invention. It is intended that all such changes, modifications and variations fall within the scope of the following appended claims and their equivalents.