Modular transformer system

• US 9,824,809 B2
• Filed: 04/07/2015
• Issued: 11/21/2017
• Est. Priority Date: 04/07/2014
• Status: Active Grant

• Current Assignee: Tstm Inc.
• Original Assignee: Tstm Inc.
• Inventors: May, Greg
• Primary Examiner(s): Chan, Tsz
• Application Number:
  US14/680,727
• Publication Number:
  US 20160012953A1
• Time in Patent Office: 959 Days
• Field of Search: 336 90, 336 92, 336 96, 336107, 336200, 336232
• CPC Class Codes: H01F 27/027 specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards

Abstract

A transformer system includes a transformer module and a base module. One or more transformer modules are detachably coupled to the base module. The transformer module includes a housing, a transformer, primary-side and secondary-side wires electrically connected to primary and secondary terminals of the transformer, a conductive tab electrically connected to a neutral terminal of the transformer, and a first coupling mechanism. The base module includes a base enclosure, a neutral connector electrically connected to a power line neutral connection, and a second coupling mechanism. The second coupling mechanism detachably engages the first coupling mechanism of the transformer module, and the conductive tab of the transformer module is electrically connected to the neutral connector of the base module when the first coupling mechanism is engaged with the second coupling mechanism.

Claims

1. A transformer system comprising:

a transformer module comprising;

a housing frame;

a transformer mounted to the housing frame and having a primary terminal, a secondary terminal, and a neutral terminal;

a primary-side wire electrically connected to the primary terminal of the transformer and extending from the housing frame to be connected to a line power;

a secondary-side wire electrically connected to the secondary terminal of the transformer and extending from the housing frame to be connected to a load; and

a first coupling mechanism, and

a base module comprising;

a base enclosure;

a neutral connector configured to be electrically connected to a power line neutral connection; and

a second coupling mechanism arranged on the base enclosure and configured to detachably engage the first coupling mechanism of the transformer module;

wherein the neutral terminal of the transformer module and the neutral connector of the base module form a connection at a conductive tab of that is inserted into a slot at a connection location when the first coupling mechanism is engaged with the second coupling mechanism, the connection being positioned along a rail extending along the base module, the connection location being among a plurality of connections along the rail, the bottom surface of the housing being configured to receive at least a portion of the rail at the connection location.

2. The system of claim 1, further comprising a second transformer module, the second transformer module comprising:

a housing frame;

a transformer located remotely from the housing frame and having a primary terminal, a secondary terminal, and a neutral terminal;

a primary-side wire electrically connected to the primary terminal of the transformer and extending from the housing frame to be connected to a line power;

a secondary-side wire electrically connected to the secondary terminal of the transformer and extending from the housing frame to be connected to a load; and

a first coupling mechanism,

wherein a neutral terminal of the transformer module and the neutral connector of the base module form a second connection at a second conductive tab that is inserted into a second slot when the first coupling mechanism of the second transformer module is engaged with the second coupling mechanism at a second connection location from among the plurality of connection locations along the rail.

3. The system of claim 1, wherein the first coupling mechanism is snap-fitted to the second coupling mechanism.

5. The system of claim 1, wherein the rail is

configured to be received in the at least one groove of the transformer module when the first coupling mechanism is engaged with the second coupling mechanism.

6. The system of claim 5, wherein the at least one groove of the transformer module is slidably engaged onto the at least one rail of the base module.

7. The system of claim 5, wherein the at least one groove of the transformer module is snap-fitted to the at least one rail of the base module as the first coupling mechanism is engaged with the second coupling mechanism.

8. The system of claim 5, wherein the neutral connector comprises a conductive clip arranged underneath the slot within the base enclosure and configured to receive the conductive tab of the transformer module through the slot, the conductive clip electrically connected to the power line neutral connection.

4. The system of clam 3, wherein the first coupling mechanism comprises a coupling button configured selectively to couple the first coupling mechanism to the second coupling mechanism or to release the first coupling mechanism from the second coupling mechanism.

9. A transformer module comprising:

a housing frame;

a transformer having a primary terminal, a secondary terminal, and a neutral terminal;

a primary-side wire electrically connected to the primary terminal and extending from the housing frame to be connected to a line power;

a secondary-side wire electrically connected to the secondary terminal and extending from the housing frame to be connected to a load; and

a coupling mechanism configured to be detachably engaged with a base module, the base module having a neutral connector configured to be electrically connected to a power line neutral connection,

wherein the transformer module, when connected to the base module, forms an electrical connection between a conductive tab and a slot, the electrical connection forming between the neutral terminal and a grounding connection of the base module at a connection location from among an array of connection locations positioned along a rail of the base module.

10. The module of claim 9, wherein the transformer is mounted within the housing frame.

11. The module of claim 9, wherein the coupling mechanism comprises at least one groove extending along a bottom surface of the housing, the at least one groove configured to receive the rail of the base module when the coupling mechanism is engaged with the base module.

12. The module of claim 11, wherein the at least one groove is snap-fitted to the at least one rail of the base module as the coupling mechanism is engaged with the base module.

14. The module of claim 11, wherein the at least one groove is slidably engaged onto the at least one rail of the base module.

13. The module of clam 12, wherein the coupling mechanism comprises a coupling button configured selectively to couple the at least one groove to the base module or to release the at least one groove from the base module.