Transformer and power supply device including the same

• US 9,824,810 B2
• Filed: 01/21/2015
• Issued: 11/21/2017
• Est. Priority Date: 08/29/2013
• Status: Active Grant

• Current Assignee: Solum Co., Ltd.
• Original Assignee: Solum Co., Ltd.
• Inventors: Eom, Jae Gen, Noh, Young Seung, Choi, Heung Gyoon, Park, Geun Young, Han, Sung Yun, Jang, Seh Hoon, Jeong, Nak Jun, Lee, Young Min, Kim, Jong Woo, Heo, Tae Won
• Primary Examiner(s): Hinson, Ronald
• Application Number:
  US14/601,718
• Publication Number:
  US 20150130578A1
• Time in Patent Office: 1,035 Days
• Field of Search: 336200
• CPC Class Codes: H01F 2027/065 Mounting on printed circuit boards
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 2027/2819 Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 27/06 Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2828 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2885 with shields or electrodes shields or electrodes for pancake coils H01F27/2871; construction of electric or magnetic shields or screens H01F27/36
• CPC Class Codes: H01F 27/32 Insulating of coils, windings, or parts thereof
• CPC Class Codes: H01F 27/323 Insulation between winding turns, between winding layers
• 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 27/327 Encapsulating or impregnating encapsulating coil and core H01F27/022

Abstract

A transformer includes a magnetic core, a first coil unit and a second coil unit. The first coil unit is disposed within the magnetic core and includes a laminated board having layers laminated therein and conductive patterns. Respective ones of the conductive patterns are disposed on the laminated layers. The second coil unit includes a conductive wire spaced apart from the conductive patterns of the laminated board by an insulating distance. The conductive wire includes a triple-insulated wire surrounded by three sheets of insulating paper to maintain the insulating distance from the conductive patterns.

Claims

1. A transformer comprising:

a coil assembly including a magnetic core and first and second coil parts disposed in the magnetic core; and

a base including an accommodation portion including a seating part having the coil assembly seated therein and a side wall protruding from the seating part,

wherein the first coil part includes a multilayer substrate formed by stacking layers having inductor patterns formed thereon,

the second coil part is disposed on at least one of upper and lower portions of the first coil part and is insulated by surrounding a conductive wire by two or more insulating papers,

the second coil part has a thickness less than that of the multilayer substrate,

the conductive wire and a conductive pattern formed on a layer of the first coil part constituting an inductor pattern closest to the second coil part are electrically insulated from each other and have an insulation distance based on the two or more insulating papers,

the side wall of the accommodation portion has a coil outlet as a passage through which the second coil part is led out to an external surface of the accommodation portion,

the transformer further comprises a first terminal portion and a second terminal portion, and

the second terminal portion includes a terminal strip supporting the second coil part led out from the accommodation portion and a fastening recess to which an end of the second coil part is fastened.

2. The transformer of claim 1, wherein the side wall has a coil lead hole formed therein, the coil lead hole being a path by which the conductive wire is led to the outside of the accommodation portion.

3. The transformer of claim 1, wherein portions of the conductive wire at which the at least two insulating papers are removed in the lead wires fastened to the fastening recess are exposed to the outside of the fastening recess to serve as terminal pins.

4. The transformer of claim 1, further comprising a plurality of insulating members interposed between the conductive wire and the magnetic core.

5. The transformer of claim 1, wherein the base includes a terminal part allowing the coil assembly to be electrically connected to a main substrate.

6. The transformer of claim 5, wherein the base includes a support part protruding from a lower surface of the accommodation portion to allow the main substrate and the lower surface of the accommodation portion to be spaced apart from each other.

7. The transformer of claim 5, wherein the terminal part includes the first terminal portion connected to the first coil part of the coil assembly and the second terminal portion connected to the second coil part of the coil assembly.

8. The transformer of claim 7, wherein the base includes a plurality of terminal pins electrically connecting the multilayer substrate and the main substrate to each other, and the plurality of terminal pins are coupled to the first terminal portion.

9. The transformer of claim 7, wherein the second terminal portion further includes a terminal stand protruding from the accommodation portion to the outside and at least one terminal pin coupled to the terminal stand.

10. The transformer of claim 9, wherein lead wires of the conductive wire are coupled to the terminal pins coupled to the terminal stand in a state in which the lead wires are dispersed based on the terminal stand.

11. The transformer of claim 9, wherein the second terminal portion has a step formed on one side of the terminal stand, and the terminal pins are coupled along the step.

12. The transformer of claim 11, wherein the second terminal portion has the step formed in a form in which a thickness of the terminal stand is reduced toward in an outward direction.