TRANSFORMER AND POWER SUPPLY MODULE WITH HIGH THERMAL EFFICIENCY

• US 20200135379A1
• Filed: 12/30/2019
• Published: 04/30/2020
• Est. Priority Date: 06/08/2017
• Status: Active Grant

• Current Assignee: Delta Electronics Company Limited (Delta Electronics Incorporated)
• Original Assignee: Delta Electronics Company Limited (Delta Electronics Incorporated)
• Inventors: LU, Zeng-Yi, YANG, Hai-Jun
• Granted Patent: US 11,581,118 B2
• Time in Patent Office: Days
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/04 Leading of conductors or axles through casings, e.g. for tap-changing arrangements
• CPC Class Codes: H01F 27/16 Water cooling
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2852 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 27/324 Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
• CPC Class Codes: H01F 27/325 Coil bobbins formers for coils in general H01F5/02
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Abstract

A transformer includes two first cores, a primary winding and a secondary winding. The secondary winding has a first section and a second section. The first section has a first outlet end, a second outlet end, and a first connection end, wherein the first outlet end and the second outlet end are located at a side of the first section, the first connection end is located at an opposite side of the first section. The second section has a third outlet end, a fourth outlet end, and a second connection end. The third outlet end and the fourth outlet end are located at a side of the second section, and the second connection end is located at an opposite side of the second section. A portion of the primary winding is located between the first section and the second section of the secondary winding.

Claims

1. A transformer comprising:

two first cores disposed opposite to each other;

at least one primary winding; and

at least one secondary winding comprising;

a first section having a first outlet end, a second outlet end, a first connection end, and a first opening, wherein the first outlet end and the second outlet end are disposed at a side of the first section, the first connection end is disposed at an opposite side of the first section; and

a second section having a third outlet end, a fourth outlet end, a second connection end, and a second opening, wherein the third outlet end and the fourth outlet end are disposed at a side of the second section, the second connection end is disposed at an opposite side of the second section, the second section is in parallel with the first section, and at least a portion of a second connection side of the second section and at least a portion of a first connection side of the first section are joined to collectively form a connection portion,

at least a portion of the at least one primary winding is disposed between the first section and the second section of the at least one secondary winding.

2. The transformer of claim 1, wherein the first outlet end is disposed opposite to the third outlet end, and the second outlet end is disposed opposite to the fourth outlet end.

3. The transformer of claim 2, wherein the first outlet end and the second outlet end constitute a first outer connection port of a first coil, the third outlet end and the fourth outlet end constitute a second outer connection port of a second coil, the first outer connection port and the second outer connection port are connected to an external circuit respectively.

4. The transformer of claim 2, wherein the first outlet end and the fourth outlet end constitute a third outer connection port of a first coil, the second outlet end and the third outlet end constitute a fourth outer connection port of a second coil, the third outer connection port and the fourth outer connection port are connected to an external circuit respectively.

5. The transformer of claim 1, wherein the secondary winding comprises a single piece of bent conductive metal sheet.

6. The transformer of claim 1, wherein the secondary winding further comprises an insulation sheet between the first section and/or the second section and the first cores.

7. The transformer of claim 1, wherein the secondary winding further comprises at least one extension portion coupled to at least one side of the connection portion.

8. The transformer of claim 7, wherein the extension portion and the connection portion are of an integrally formed piece.

9. The transformer of claim 1, wherein the first section, the at least one primary winding, and the second section are sequentially arranged.

10. The transformer of claim 1, wherein the at least one secondary winding comprises a first secondary winding and a second secondary winding, the at least one primary winding comprises a first primary winding, a second primary winding, and a third primary winding, wherein the first section of the first secondary winding, the first primary winding, the second section of the first secondary winding, the second primary winding, the first section of the second secondary winding, the third primary winding, and the second section of the second secondary winding are sequentially arranged.

11. The transformer of claim 1, wherein the at least one secondary winding comprises a first secondary winding and a second secondary winding, the at least one primary winding comprises a first primary winding, a second primary winding, and a third primary winding, wherein the first section of the first secondary winding, the first primary winding, the first section of the second secondary winding, the second primary winding, the second section of the first secondary winding, the third primary winding, and the second section of the second secondary winding are sequentially arranged.

12. The transformer of claim 1, wherein the first outlet end, the second outlet end, the third outlet end and the fourth outlet end all include a raised portion having a height.

13. The transformer of claim 1, further comprising at least one bobbin, wherein the primary winding comprises a plurality of coils respectively wound in slots of the bobbin, and the bobbin has a convex position block that correspondingly engages the first opening and/or the second opening when the transformer is assembled.

14. The transformer of claim 13, wherein the coils of the primary winding constitute a triple insulation wire.

15. The transformer of claim 1, further comprising an inductor having:

a second core disposed at one side of the first cores; and

at least one inductor winding disposed between the second core and the first cores.

16. A power supply module comprising the transformer of claim 1.

17. The power supply module of claim 16, further comprising a chamber that accommodates the transformer.

18. The power supply module of claim 17, further comprising a thermal resin filled into the chamber and at least partially wrapped around the transformer.

19. The power supply module of claim 18, further comprising a heat dissipation plate disposed under and/or around the chamber to dissipate heat out of the chamber.

20. The power supply module of claim 19, wherein the heat dissipation plate is a water-cooling plate.