Transformer and display device using the same

There is provided a transformer capable of significantly reducing leakage inductance while satisfying safety standards. The transformer includes: a winding part having a plurality of coils wound on an outer peripheral surface of a pipe shaped body part while being stacked thereon; and a terminal connection part extended from one end of the winding part in an outer diameter direction thereof and having a plurality of external connection terminals coupled to a distal end thereof, the terminal connection part including at least one catching groove formed such that the coils are led to the outside of the winding part therethrough, and a lead wire of at least one of the coils being led to the outside of the winding part while maintaining a winding direction of the coils.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority of Korean Patent Application No. 10-2011-0065120 filed on Jun. 30, 2011, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a transformer, and more particularly, to a transformer capable of significantly reducing leakage inductance while satisfying safety standards.

2. Description of the Related Art

Various kinds of power supplies are required in various electronic devices such as a television (TV), a monitor, a personal computer (PC), an office automation (OA) device, and the like. Therefore, these electronic devices generally include power supplies converting alternating current (AC) power supplied from the outside into power having an appropriate level for individual electronic appliances.

Among power supplies, a power supply using a switching mode (for example, a switched-mode power supply (SMPS)) has mainly been used. An SMPS basically includes a switching transformer.

The switching transformer generally converts AC power of 85 to 265 V into direct current (DC) power of 3 to 30 V through high frequency oscillation at 25 to 100 KHz. Therefore, in the switching transformer, a core and a bobbin may be significantly reduced in size as compared to a general transformer converting AC power of 85 to 265 V into DC current of 3 to 30 V through frequency oscillation at 50 to 60 Hz, and low voltage and low current DC power may be stably supplied to an electronic appliance. Therefore, the switching transformer has been widely used in electronic appliances that have tended to be miniaturized.

This switching transformer should be designed to have relatively low leakage inductance in order to increase energy conversion efficiency. However, in accordance with the miniaturization of the switching transformer, it is not easy to design a switching transformer having small leakage inductance.

In addition, in the case in which a small-sized transformer, as described above, is manufactured, since a primary coil and a secondary coil are disposed to be immediately adjacent to each other, it may be difficult to satisfy safety standards (that is, those of Underwriters Laboratories (UL)) due to the arrangement thereof.

SUMMARY OF THE INVENTION

An aspect of the present invention provides a small-sized switching transformer.

Another aspect of the present invention provides a transformer capable of significantly reducing leakage inductance.

Another aspect of the present invention provides a transformer satisfying safety standards with regard to a primary coil and a secondary coil.

According to an aspect of the present invention, there is provided a transformer including: a winding part having a plurality of coils wound on an outer peripheral surface of a pipe shaped body part while being stacked thereon; and a terminal connection part extended from one end of the winding part in an outer diameter direction thereof and having a plurality of external connection terminals coupled to a distal end thereof, the terminal connection part including at least one catching groove formed such that the coils are led to the outside of the winding part therethrough, and a lead wire of at least one of the coils being led to the outside of the winding part while maintaining a winding direction of the coils.

A length of the catching groove may be larger than a thickness of the terminal connection part in which the catching groove is formed.

When the length of the catching groove is regarded as W and the thickness of the terminal connection part in which the catching groove is formed is regarded as T, W/T>1.

The lead wire led through the catching groove may form an angle of less than 45 degrees with respect to the coils wound in the winding part while being led.

At least two of the lead wires led through the catching groove may be disposed to intersect each other in an X shape in the catching groove.

The terminal connection part may further include at least one lead groove formed in a radial direction, and the catching groove may be formed in the lead groove in a manner in which a width of the lead groove is extended.

The winding part may include a plurality of winding spaces formed by at least one partition wall on the outer peripheral surface of the body part, and the coils may be wound such that they are disposed in the plurality of spaces divided by the partition wall in a dispersed scheme.

The partition wall may include at least one skip groove, and the coils may be wound while skipping the partition wall via the skip groove.

The coils may include a plurality of primary coils and a plurality of secondary coils, and the catching groove may be formed in a position corresponding to the primary coil or the secondary coil that is continuously wound in the winding part while being stacked therein.

The coils may be continuously wound so that the plurality of secondary coils are interposed between the plurality of primary coils while being stacked therebetween.

At least one of the primary coil and the secondary coil may be a multi-insulated coil.

The terminal connection part may include at least one catching protrusion protruded from an outer surface thereof, and the lead wire led through the catching groove may be disposed in an altered direction while supporting the catching protrusion.

The catching protrusion may be formed in a position adjacent to the catching groove.

At least one of the catching grooves may be a double catching protrusion having a step formed at a side thereof.

The double catching protrusion may include: a base protrusion protruded so that a distal end thereof has a predetermined area and simultaneously supports at least two of the lead wires using the distal end thereof and a sidewall thereof; and a support protrusion further protruded from any one portion in the distal end of the base protrusion.

The catching groove may be formed as an elongated cut in a winding direction of the coils or formed to have an arc, and the leads wires of the coils may be led to the outside while crossing the catching groove in a length direction of the catching groove.

According to another aspect of the present invention, there is provided a transformer including: a winding part having a plurality of coils wound on an outer peripheral surface of a pipe shaped body part while being stacked thereon; and a terminal connection part extended from one end of the winding part in an outer diameter direction thereof and having a plurality of external connection terminals coupled to a distal end thereof, a lead wire of at least one of the coils being led to the outside of the terminal connection part while forming an angle less than 45 degrees with respect to the coils wound in the winding part.

According to another aspect of the present invention, there is provided a display device including: a switching mode power supply including at least one transformer as described above mounted on a substrate; a display panel receiving power supplied from the switching mode power supply; and covers protecting the display panel and the switching mode power supply.

A coil of the transformer may be wound so as to be parallel to the substrate of the switching mode power supply.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The terms and words used in the present specification and claims should not be interpreted as being limited to typical meanings or dictionary definitions, but should be interpreted as having meanings and concepts relevant to the technical scope of the present invention based on the rule according to which an inventor can appropriately define the concept of the term to appropriately describe the method he or she knows for carrying out the invention. Therefore, the configurations described in the embodiments and drawings of the present invention are merely the embodiments, but do not represent all of the technical spirit of the present invention. Thus, the present invention should be construed as including all the changes, equivalents, and substitutions included in the spirit and scope of the present invention at the time of the filing of this application.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. At this time, it is noted that like reference numerals denote like elements in appreciating the drawings. Moreover, detailed descriptions related to well-known functions or configurations will be ruled out in order not to unnecessarily obscure the subject matter of the present invention. Based on the same reason, it is to be noted that some components shown in the drawings are exaggerated, omitted or schematically illustrated, and the size of each component does not accurately reflect its real size.

Meanwhile, safety standards disclosed in the present embodiment refer to standards defined by Underwriters Laboratories Inc. with respect to a structure, an embedded component, a wiring method, and the like, of an electronic device. However, the present invention is not limited thereto.

FIG. 1is a perspective view schematically showing a transformer according to an embodiment of the present invention;FIG. 2Ais a perspective view schematically showing a bobbin of the transformer shown inFIG. 1; andFIG. 2Bis a perspective view schematically showing a lower surface of the bobbin shown inFIG. 2A.

FIG. 3Ais a bottom view showing the lower surface of the bobbin shown inFIG. 2A; andFIG. 3Bis a bottom view showing a state in which a coil is wound in the bobbin shown inFIG. 3A.FIG. 4is a cross-sectional view taken along line A-A′ ofFIG. 3A.

Referring toFIGS. 1 through 4, the transformer100according to the embodiment of the present invention, an insulating type switching transformer, may include a bobbin10, a core40, and a coil50.

The bobbin10may include a winding part12having the coil50wound therein and a terminal connection part20formed at one end of the winding part12.

The winding part12may include a body part13having a pipe shape and a flange part15extended from both ends of the body part13in an outer diameter direction.

The body part13may include a through hole11formed in an inner portion thereof and at least one partition wall14formed on an outer peripheral surface thereof, wherein the through hole11includes the core40partially inserted thereinto and the partition wall14partitions a space in a length direction of the body part13. In this configuration, the coil50may be wound in each of the spaces partitioned by the partition wall14.

The winding part12according to the present embodiment may include one partition wall14. Therefore, the winding part12according to the present embodiment may include two winding spaces12aand12bas partitioned spaces. However, the present invention is not limited thereto, and a number of partitions may be formed and used through a number of partition walls14as needed.

In addition, the partition wall14according to the present embodiment may include at least one skip groove14aformed therein so that the coil50wound in a specific space, for example, an upper space12aamong the two winding spaces12aand12bas the partitioned spaces, may skip the partition wall14to thereby be wound in another space, for example, a lower space12bamong the two winding spaces12aand12b.

The skip groove14amay be formed such that a portion of the partition wall14is entirely removed so that an outer surface of the body part13is exposed. In addition, the skip groove14amay have a width wider than a thickness (that is, a diameter) of the coil50. The skip groove14amay be formed as a pair, corresponding to positions of terminal connection parts20aand20bto be described below.

The partition wall14according to the present embodiment may be provided in order to approximately uniformly dispose and wind the coil50in the winding spaces12aand12b. Therefore, the partition wall may have various thicknesses and be formed of various materials, as long as a shape thereof may be maintained.

Meanwhile, although the case in which the partition wall14is formed integrally with the bobbin10is described by way of example in the present embodiment, the present invention is not limited thereto, but may be variably modified. For example, the partition wall14may also be formed as an independent separate member and be then coupled to the bobbin20.

The partition wall14according to the present embodiment may have approximately the same shape as that of the flange part15.

The flange part15may be protruded in a shape in which it is extended from both ends, that is, upper and lower ends, of the body part13in the outer diameter direction. The flange part15according to the present embodiment may be divided into an upper flange part15aand a lower flange part15baccording to a formation position thereof.

In addition, an outer peripheral surface of the body part13, that is, a space between the upper and lower flange parts15aand15bmay be formed as the winding spaces12aand12bin which the coil50is wound. Therefore, the flange part15may serve to protect the coil50from the outside and secure insulation properties between the coil50and the outside, while simultaneously serving to support the coils50in the winding spaces12aand12bat both sides thereof.

The terminal connection part20may be formed in the lower flange part15b. More specifically, the terminal connection part20according to the present embodiment may be formed to have a shape in which it is protruded from the lower flange part15bin the outer diameter direction in order to secure an insulation distance.

However, the present invention is not limited thereto. That is, the terminal connection part20may also be formed to have a shape in which it is protruded downwardly of the lower flange part15b.

Meanwhile, referring to the accompanying drawings, since the terminal connection part20according to the present embodiment is formed to have a shape in which it is partially extended from the lower flange part15b, it is difficult to precisely distinguish between the lower flange part15band the terminal connection part20. Therefore, in the terminal connection part20according to the present embodiment, the lower flange part15bitself may also be perceived as the terminal connection part20.

External connection terminals30to be described below may be connected to the terminal connection part20to be protruded outwardly.

In addition, the terminal connection part20according to the present embodiment may include a primary terminal connection part20aand a secondary terminal connection part20b. Referring toFIG. 1, the case in which the primary terminal connection part20aand the secondary terminal connection part20bare respectively extended from both ends of the lower flange part15bexposed to the outside of the core40is described by way of example in the present embodiment. However, the present invention is not limited thereto but may be variably modified. For example, the primary terminal connection part20aand the secondary terminal connection part20bmay also be formed on any one end of the lower flange part15bor be formed in positions adjacent to each other.

In addition, the terminal connection part20according to the present embodiment may include a lead groove25, a catching groove26, guide protrusions27, and catching protrusions28in order to guide a lead wire L of the coil50wound in the winding part12to the external connection terminal30.

The lead groove25may be used in the case in which the lead wire L of the coil50wound in the winding part12is led to a lower portion of the terminal connection part20. To this end, the lead groove25according to the present embodiment may be formed to have a shape in which portions of the terminal connection part20and the lower flange part15bare entirely removed so that the outer surface of the body part13is exposed.

In addition, the lead groove25may have a width wider than thicknesses (that is, diameters) of a primary coil51and a secondary coil25.

Particularly, the lead groove25according to the present embodiment may be formed in a position corresponding to that of the skip groove14aof the partition wall14described above. More specifically, the lead groove25may be formed in a position at which the skip groove14aprojects downwardly.

The lead groove25may be formed as a pair, corresponding to the position of the terminal connection part20, similar to the skip groove14a. In this case, two lead grooves25may be a first lead groove25athrough which the primary coil is led and a second lead groove25bthrough which the secondary coil lead groove25bis led. However, the present invention is not limited thereto. That is, a number of lead grooves25may also be formed at various positions as needed.

The catching groove26may be formed in the lead groove25and be formed to have a shape in which a width of the lead groove25is extended. That is, the catching groove26may be formed as an elongated groove having a shape in which it is formed across the lead groove25and has a width of a size at which the coil50may be led to the outside while penetrating therethrough.

In addition, the catching groove26may be formed to have a shape in which it has a width extended from the lead groove25in both of two opposite directions or be formed to have a shape in which it has a width extended in any one direction.

A lower portion of the catching groove26, that is, an edge portion thereof connected to a lower surface of the terminal connection part20may be formed as an inclined surface or a curved surface through chamfering, or the like. Therefore, a phenomenon in which the lead wire L led through the catching groove26is bent by the edge portion of the catching groove26may be significantly reduced.

In addition, the catching groove26according to the present embodiment may be formed under the primary coil51and the secondary coil52continuously wound in the winding part12in a shape in which the terminal connection part20is cut in a winding direction of each coil50. That is, although the catching groove26is formed by being cut in a linear manner in the present embodiment, the present invention is not limited thereto. That is, the catching groove26may also be formed by being cut to have an arc according to a winding shape of the coil50wound in a ring shape.

In addition, the catching groove26according to the present embodiment may include two catching grooves26aand26cformed in the first lead groove25athrough which the primary coil51is led and one catching groove26bformed in the second lead groove25bthrough which the secondary coil52is led. A configuration of this catching groove26will be described in more detail in a description of the coil50below.

Meanwhile, in the transformer100according to the present embodiment, leakage inductance generated at the time of driving thereof may be significantly reduced by the lead groove25and the catching groove26according to the present embodiment.

In the case of the transformer according to the related art, generally, the lead wire of the coil is configured such that it is led to the outside along an inner wall surface of a space in which the coil is wound, such that the wound coil and the lead wire of the coil are in contact with each other.

Therefore, the coil is wound such that it is bent at a portion at which it contacts the lead wire thereof, and this bending, that is, non-uniform winding, of the coil causes an increase in leakage inductance.

However, in the transformer100according to the present embodiment, the lead wire L of the coil50is not disposed in the winding part12, but is directly led from a position in which it is wound, to an outer portion of the winding part12, that is, the lower portion of the terminal connection part20, through the lead groove25and the catching groove26in a vertical direction.

Therefore, the coil50wound in the winding part12may be entirely uniformly wound therearound, such that the leakage inductance generated due to the bending of the coil50described above, or the like, may be significantly reduced.

A plurality of catching protrusions28may be protruded from one surface of the terminal connection part20. The case in which the plurality of catching protrusions28are protruded downwardly from the outer surface (the lower surface) of the terminal connection part20is described by way of example in the present embodiment.

The plurality of catching protrusions28are provided to guide the lead wire L of the coil50wound in the winding part12so that the lead wire L may be easily disposed in a direction from the lower portion of the terminal connection part20to the external connection terminal30, as shown inFIG. 2B. Therefore, the plurality of catching protrusions28may be protruded beyond a diameter of the lead wire L of the coil50so as to firmly support the coil50supported by the plurality of catching protrusions28while being caught by the plurality of catching protrusions28.

Due to the catching protrusions28, the lead wires L led from the catching groove26may be disposed in various directions, as needed.

Particularly, the plurality of catching protrusions28according to the present embodiment may be provided in order to easily change a disposition direction of the lead wires L led from the catching groove26in the winding direction.

Therefore, in the case in which all of the external connection terminals30to which the lead wires L are connected are disposed in a leading direction of the lead wires L, led from the catching groove26as in the secondary terminal connection part20b, this catching protrusion28may be omitted. However, in the case in which corresponding external connection terminals30are disposed in an opposite direction to the leading direction of the lead wires L as in the primary terminal connection part20a, the lead wires L may be disposed at an altered direction while supporting the plurality of catching protrusions28.

The direction in which the lead wires L are provided, a direction opposite to the leading direction thereof while supporting the plurality of catching protrusions28, may be additionally reversed, with regard to a disposition direction thereof, to a direction in which the external connection terminals30are connected while supporting another catching protrusion28.

To this end, at least one of the catching protrusions28according to the present embodiment may be disposed such that it is adjacent to the catching groove26.

Meanwhile, at least one of the catching protrusions28according to the present embodiment may be configured to have a step formed at least one side thereof.

FIG. 5is a partially enlarged perspective view of a double catching protrusion shown inFIG. 3B. Referring toFIG. 5, a catching protrusion having the step, (hereinafter, a double catching protrusion29), may include a base protrusion29aand a support protrusion29b.

The base protrusion29amay be protruded so that a distal end thereof has a predetermined area. Therefore, the base protrusion29amay not only support a lead wire L1through a sidewall thereof but also support a lead wire L2through the distal end thereof, similar to the other catching protrusion28. That is, the base protrusion29amay simultaneously support at least two lead wires L1and L2.

This base protrusion29amay be protruded to a height higher than a thickness of the lead wire L1. Therefore, the lead wire L1supported by the sidewall of the base protrusion29aand the lead wire L2supported by the distal end of base protrusion29amay be disposed to be spaced apart from each other by a predetermined interval.

The support protrusion29bmay be further protruded from any one portion in the distal end of the base protrusion29a. The support protrusion29bmay have a shape, a size, and the like, similar to those of other catching protrusions28except that it is protruded from the distal end of the base protrusion29a.

The support protrusion29bmay prevent the lead wire L supported by the distal end of the base protrusion29afrom moving in a specific direction. In addition, the support protrusion29bmay prevent the lead wire L supported by the sidewall of the base protrusion29afrom being easily separated from the double catching protrusion29.

The double catching protrusion29according to the present embodiment configured as described above may be provided in order to prevent the lead wires L from contacting while intersecting each other in a process in which the lead wires L are disposed on the lower surface of the terminal connection part20.

As shown inFIG. 3B, as the disposal of the lead wires L becomes complicated, the lead wires L may be disposed so as to intersect each other while contacting each other. Therefore, in order to prevent this phenomenon, the transformer100according to the present embodiment may include the above-mentioned double catching protrusion29.

Since the transformer100includes the double catching protrusion29, a specific lead wire L1led from the catching groove26may be disposed in an altered direction while being supported by the sidewall formed by both the base protrusion29aand the support protrusion29b.

In addition, another lead wire L2disposed so as to intersect with the above-mentioned specific lead wire L1may be disposed while being supported by the distal end of the base protrusion29a. Therefore, since the specific lead wire L1and another lead wire L2intersect each other while being spaced apart from each other by a predetermined interval, interference therebetween may be significantly reduced.

A plurality of guide protrusions27may be formed to be protruded from one surface of the terminal connection part20in parallel. The case in which the plurality of guide protrusions27are protruded downwardly from the lower surface of the terminal connection part20is described by way of example in the present embodiment.

The guide protrusions27may be formed at a distal end of the terminal connection part20so as to be protruded in parallel with each other corresponding to coupling positions of the external connection terminals30. Here, the respective guide protrusions27may have the same shape or have various shapes as needed as in the guide protrusions27formed at the secondary terminal connection part20b.

The guide protrusion27is to guide the lead wire L of the coil50led from the catching groove26or the catching protrusion28so that the lead wire L may be easily disposed in the external connection terminal30, as shown inFIG. 2B. Therefore, the guide protrusions27may be protruded beyond a diameter of the lead wire L of the coil50so as to guide the coil50disposed therebetween while firmly supporting the coil50.

Due to these guide protrusions27, the lead wires L led to the outside of the terminal connection part20through the catching groove26may be disposed in the altered direction while supporting the catching protrusion28and electrically connected to the external connection terminals30through a space between the guide protrusions27.

The terminal connection part20according to the present embodiment configured as described above was derived in consideration of the case in which the coil50is automatically wound in the bobbin10.

That is, due to the configuration of the bobbin10according to the present embodiment, a process of winding the coil50in the bobbin10, a process of skipping the lead wire L of the coil50to the lower portion of the bobbin10via the skip groove25and the catching groove26, a process of changing a route of the lead wire L through the guide protrusion27to lead the lead wire L in a direction in which the external connection terminal30is formed and then connecting the lead wire L to the external connection terminal30, and the like, may be automatically performed through a separate automatic winding device (not shown).

The terminal connection part20may include a plurality of external connection terminals30connected thereto. The external connection terminals30may be protruded outwardly from the terminal connection part20and be variously shaped, according to a shape or a structure of the transformer100or a structure of a substrate on which the transformer100is mounted.

That is, the external connection terminals30according to the present embodiment may be connected to the terminal connection part20so that they are protruded from the terminal connection part20in an outer diameter direction of the body part13. However, the present invention is not limited thereto. The external connection terminals30may be formed in various positions as needed. For example, the external connection terminals30may be connected to the terminal connection part20so that they are protruded downwardly from the lower surface of the terminal connection part20.

In addition, the external connection terminal30according to the present embodiment may include an input terminal30aand an output terminal30b.

The input terminal30amay be connected to the primary terminal connection part20aand be connected to the lead wire L of the primary coil51to supply power to the primary coil51. In addition, the output terminal30bmay be connected to the secondary terminal connection part20band be connected to the lead wire L of the secondary coil52to supply output power set according to a turns ratio between the secondary coil52and the primary coil51to the outside.

The external connection terminal30according to the present embodiment may include a plurality of (for example, four) input terminals30aand a plurality of (for example, seven) output terminals30b. This configuration was derived because the transformer100according to the present embodiment is configured so that a plurality of coils50are wound together in a single winding part12while being stacked therein. Therefore, in the transformer100according to the present embodiment, the number of external connection terminals30is not limited to the above-mentioned number.

In addition, the input terminal30aand the output terminal30bmay have the same shape or have different shapes as required. In addition, the external connection terminal30according to the present embodiment may be variously modified as long as the lead wire L may be more easily connected thereto.

The bobbin10according to the present embodiment as described above may be easily manufactured by an injection molding method, but is not limited thereto. In addition, the bobbin10according to the present embodiment may be formed of an insulating resin and be formed of a material having high heat resistance and high voltage resistance. As a material of the bobbin10, polyphenylenesulfide (PPS), liquid crystal polyester (LCP), polybutyleneterephthalate (PBT), polyethyleneterephthalate (PET), phenolic resin, and the like, may be used.

The core40may be partially inserted into the through hole11formed in an inner portion of the bobbin10and be electromagnetically coupled to the coil50to form a magnetic path.

The core40according to the present embodiment may be configured as a pair. A pair of cores40may be partially inserted into the through hole11of the bobbin10to thereby be coupled to each other while facing each other. As the core40, an ‘EE’ core, an ‘EI’ core, a ‘UU’ core, a ‘UI’ core, or the like, according to a shape thereof, may be used.

In addition, the core40according to the present embodiment may have an hourglass shape in which a portion contacting the flange part15is partially concave, according to a shape of an insulating rib19of the bobbin10, described above. However, the present invention is not limited thereto.

The core40may be formed of Mn—Zn based ferrite having higher permeability, lower loss, higher saturation magnetic flux density, higher stability, and lower production costs, as compared to other materials. However, in the embodiment of the present invention, a shape or a material of the core40is not limited.

Meanwhile, although not shown, in order to secure insulation properties between the coil50wound in the bobbin10and the core40, insulating tape may be interposed between the bobbin10and the core40.

The insulating tape may be interposed between the bobbin part10and the core40corresponding to the entire inner surface of the core40facing the bobbin10or be partially interposed therebetween only at a portion at which the coil50and the core40face each other

The coil50may be wound in the winding part12of the bobbin10and include the primary and secondary coils.

Referring toFIGS. 6A through 6C, the primary coil51may include a plurality of coils Np1, Np2, and Np3that are electrically insulated from each other. The case in which the primary coil51is formed by winding each of three independent coils Np1, Np2, and Np3in a single winding part12is described by way of example in the present embodiment. Therefore, in the primary coil51according to the present embodiment, a total of six lead wires L may be led out and connected to the external connection terminals30. Meanwhile, for convenience of description, only a few lead wires L are representatively shown inFIG. 1.

Referring toFIG. 6A, a case in which the primary coil51according to the present embodiment includes the coils Np1, Np2, and Np3that have a similar thickness is shown. However, the present invention is not limited thereto. Each of the coils Np1, Np2, and Np3configuring the primary coil51may also have different thicknesses as needed. In addition, the respective coils Np1, Np2, and Np3may have the same amount of turns or have differing amounts of turns as needed.

Further, in the transformer100according to the present invention, when voltage is applied to at least any one (for example, Np2or Np3) of the plurality of primary coils Np1, Np2, and Np3, voltage may also be provided to the other primary coil (for example Np1) by electromagnetic induction. Therefore, the transformer may also be used in a display device to be described below.

As described above, in the transformer100according to the present embodiment, the primary coil51is configured of the plurality of coils Np1, Np2, and Np3, such that various voltages may be applied and provided through the secondary coil52bcorrespondingly.

Meanwhile, the primary coil51according to the present embodiment is not limited to the three independent coils Np1, Np2, and Np3as in the case according to the present embodiment, but may include various amounts of coils as needed.

The secondary coil52is wound in the winding part12, similar to the primary coil51. Particularly, the secondary coil52according to the present embodiment may be wound between the primary coils51while being sandwiched therebetween.

The secondary coil52may be formed by winding a plurality of coils electrically insulated from each other, similar to the primary coil51.

More specifically, the case in which the secondary coil52includes four independent coils Ns1, Ns2, Ns3, and Ns4electrically insulated from each other is described by way of example in the present embodiment. Therefore, in the secondary coil52according to the present embodiment, a total of eight lead wires L may be led and connected to the external connection terminals30.

In addition, the respective coils Ns1, Ns2, Ns3, and Ns4of the secondary coil52may have the same thickness or coils having different thicknesses and also have the same amounts of turns or have a different amount of turns as needed.

The respective individual coils Np1to Ns4according to the present embodiment may be wound so that they are disposed within the spaces12aand12bdefined by the partition wall14in an approximately uniform dispersal scheme.

More specifically, the respective coils Np1to Ns4may be wound to have the same amount of turns in each of upper and lower winding spaces12aand12band may be disposed to form vertically identical layers as shown inFIG. 6A. Therefore, the respective coils Np1to Ns4wound in the upper and lower winding spaces12aand12bmay be wound to have the same shape.

Here, in the case in which the turn of the respective coils Np1to Ns4is set as an odd number, corresponding coils Np1to Ns4may be wound so as to have differences in amounts of turns in the ratio in 10% of a total turn thereof.

This configuration is to significantly reduce the generation of the leakage inductance in the transformer100according to a wound state of the coil50.

Generally, when the coils are wound in the winding part of the bobbin, in the case in which the coils are not entirely wound uniformly, but are wound while being inclined toward one side or while being non-uniformly disposed, the leakage inductance in the transformer may be increased. In addition, this defect may be intensified as the space of the winding part is increased.

Therefore, in the transformer100according to the present embodiment, the winding part12may be partitioned into several spaces12aand12bby the partition wall14in order to significantly reduce the leakage inductance generated due to the above-mentioned reason. In addition, the coils50may be wound as uniformly as possible in the respective winding spaces12aand12b.

For example, in the case in which Ns1has a total of 18 turns, Ns1may be wound nine times in the upper winding space12aand nine times in the lower winding space12bsuch that it is disposed in a uniform dispersal scheme.

Further, in a case in which the turns are set to be wound in odd numbers (for example, 51 times), Ns1may be wound 23 times in the upper winding space12aand be wound 28 times in the lower winding space12bso as to have a difference in a turns ratio of 10%, as described above.

Meanwhile, referring to the accompanying drawings, in the case of the present embodiment, Ns1is not densely wound, but is wound eight times in a first layer and is wound ten times in a second layer. Therefore, since both of two lead wires (not shown) of Ns1are directed to a lower portion of the winding part12, they may be easily led to the terminal connection part20and connected to the external connection terminal30.

Although the accompanying drawings show the above-mentioned winding structure only with respect to Ns1for convenience of description, the present invention is not limited thereto. The above-mentioned winding structure may also be easily applied to other coils.

As described above, in the case of the transformer100according to the present embodiment, even in the case that the coil (for example, Ns1) may not be densely wound within the winding part12, due to turns or a thickness of the coil smaller than widths of the winding spaces12aand12b, the winding part12is partitioned into a plurality of spaces12aand12b, such that the coil (for example, Ns1) may be wound so as to be disposed at the same position within the respective winding spaces12aand12bin a distributed scheme without being inclined toward any one side.

In the transformer100according to the present embodiment as described above, the respective independent coils Np1to Ns4may be disposed in the upper and lower winding spaces12aand12bin a uniformly distributed scheme according to the winding scheme and the structure of the bobbin10described above. Therefore, in the entire winding part12, a phenomenon in which the coils Np1to Ns4are wound while being inclined toward any one side or are non-uniformly wound while being spaced apart from each other may be prevented, whereby the leakage inductance generated due to the non-uniform winding of the coils Np1to Ns4may be significantly reduced.

Meanwhile, as shown inFIGS. 6A and 6B, the catching groove26according to the present embodiment may be formed corresponding to contact surfaces C1and C2between the primary coil51and the secondary coil52continuously wound in the winding part12while being stacked therein, that is, positions through which the lead wire L is led.

Here, an outer peripheral surface and an inner peripheral surface of the primary coil51and the secondary coil52that are continuously wound indicate a ring shape outer peripheral surface and inner peripheral surface formed by winding the coils50in the winding part12.

In addition, the contact surfaces C1and C2indicate contact surfaces between the outer peripheral surface or the inner peripheral surface of the primary coil51and the outer peripheral surface or the inner peripheral surface of the secondary coil52.

According to the present embodiment, since Np2, as well as Np3and Np1are wound while being separated from each other, the primary coil51may have two outer peripheral surfaces and inner peripheral surfaces (an outer peripheral surface and an inner peripheral surface by Np2, and an outer peripheral surface and an inner peripheral surface by Np1and Np3).

On the other hand, since four individual coils Ns1to Ns4are continuously wound while being stacked, the secondary coil52may have only one outer peripheral surface (that is, an outer peripheral surface by Ns4) and one inner peripheral surface (that is, an inner peripheral surface by Ns1). Here, both of the outer peripheral surface C2and the inner peripheral surface C1of the secondary coil52may be formed as the contact surfaces C1and C2.

As shown in the accompanying drawings, the catching groove26according to the present embodiment may include a first catching groove26a, a second catching groove26b, and a third catching groove26c, corresponding to each of the coils50. Here, the first catching groove26aand the third catching groove26cmay be extended from the first lead groove25a, and the second catching groove26bmay be extended from the second lead groove25b.

In addition, the first catching groove26amay be formed in a position (that is, a lower portion) corresponding to Np2, the second catching groove26bmay be formed in a position corresponding to all of the secondary coils52, and the third catching groove26cmay be formed in a position corresponding to Np3and Np1.

FIG. 7is a cross-sectional view taken along line C-C′ ofFIG. 3B. Referring toFIG. 7, the catching groove26according to the present embodiment may have a length W, larger than a thickness T of the terminal connection part. Therefore, an angle θ formed by the length W of the catching groove26and the thickness T of the terminal connection part may be less than 45 degrees.

Therefore, the lead wire L of the coil50led to the outside of the terminal connection part20along the catching groove26within the winding part12may be led while lengthily intersecting with the catching groove26in a length direction of the catching groove26, such that it is led while forming an angle of less than 45 degrees with respect to another coil50wound in the winding part12.

This configuration of the catching groove26according to the present embodiment is to satisfy safety standards (that is, those of Underwriters Laboratories (UL)) with regard to the primary coil51and the secondary coil52with respect to the lead wires L led from the winding part12.

According to the UL safety standards, in the case in which the primary coil51and the secondary coil52contact each other while under tension, an angle (an acute angle) formed in a portion at which the primary coil51and the secondary coil52intersect each other needs to be set to be less than 45 degrees.

Therefore, when the angle formed by the lead wires L of the primary coil51and the secondary coil52is 45 degrees or more, UL safety standards are not satisfied.

As described above, in the transformer100according to the present embodiment, the lead wire L may be led to the outer surface of the terminal connection part20and be then coupled to the external connection terminal30.

Here, in the case in which the lead wires of the specific coil (for example, the lead wire of Ns4that is the secondary coil) is led directly downwardly from the above-mentioned contact surfaces C1and C2, the lead wires may form an angle of 90 degrees in a state in which they contact another order coil (for example, Np3or Np2that is the primary coils) that is continuously wound. In this case, the above-mentioned UL safety standards are not satisfied.

Therefore, in order to solve this defect, in the transformer100according to the present embodiment, the lead wires L may be led in a manner in which they cross the catching groove26in the length direction thereof as described above. That is, the lead wires is not led directly downwardly from the winding part12, but may be obliquely led so as to have a predetermined inclination in the winding direction. As described above, since the length W of the catching groove26is larger than the thickness T of the terminal connection part30, the lead wire L may form an angle of less than 45 degrees with regard to the coils50wound in the winding part12while being led. Therefore, the above-mentioned UL standards may be satisfied.

Through the above-mentioned configuration, at least two lead wires led through one catching groove26may be disposed so as to intersect each other in an X shape in one catching groove26, as shown inFIG. 7.

In addition, as the coils Np1to Ns4according to the present embodiment, a general insulated coil (for example, a polyurethane wire), or the like, and a twisted pair wire type coil formed by twisting several strands of wires (for example, a Litz wire, or the like) may be used. In addition, a multi-insulated coil (for example, a triple insulated wire (TIW)) having high insulation properties may be used. That is, a kind of the coil may be selected as needed.

Particularly, in the transformer100according to the present embodiment, since all (or some) of the respective individual coils are formed of the multi-insulated wire such as the TIW, or the like, insulation properties between the individual coils may be secured. Therefore, insulating tape that has been used in order to insulate the coils of the transformer according to the related art may be omitted.

The multi-insulated wire is a coil of which insulation properties is increased by forming an insulator having several layers (for example, three layers) on an outer portion of a conductor. When the triple insulated coil51bis used, insulation properties between a conductor and the outside are easily secured, whereby an insulation distance between the coils may be significantly reduced. However, this multi-insulated wire may have increased manufacturing costs, as compared to a general insulated coil (for example, a polyurethane-insulated wire).

Therefore, in the transformer according to the present embodiment, in order to significantly reduce manufacturing costs and reduce a required manufacturing process, only any one of the primary and secondary coils51and52may be the multi-insulated coil.

Again referring toFIG. 5, in the transformer100according to the present embodiment, the case in which the primary coils51are multi-insulated coils is described byway of example. In this case, the multi-insulated coils, which are the primary coils51, may be disposed at each of the innermost and outmost portions of the coils50wound in the winding part12while being stacked therein.

When the multi-insulated coils are disposed at each of the innermost and outmost portions of the coils50wound as described above, the multi-insulated coils, which are the primary coils, may serve as an insulating layer between the secondary coils52, which are general insulated coils, and the outside. Therefore, the insulation properties between the outside and the secondary coil52may be easily secured.

Meanwhile, although the case in which the multi-insulated coils, which are the primary coils51, are disposed at both of the innermost and outmost portions of the coils50is described by way of example in the present embodiment, the present invention is not limited thereto. That is, the multi-insulated coils may also be selectively disposed only at any one of the innermost and outmost portions of the coils50as needed.

FIG. 8is an exploded perspective view schematically showing a flat panel display device according to the embodiment of the present invention.

Referring toFIG. 8, the flat panel display device1according to the embodiment of the present invention may include a display panel4, a switching mode power supply (SMPS)5having the transformer100mounted therein, and covers2and8.

The covers2and8may include a front cover2and a back cover8and may be coupled to each other to thereby form a space therebetween.

The display panel4may be disposed in an internal space formed by the covers2and8. As the display panel4, various flat panel display panels such as a liquid crystal display (LCD), a plasma display panel (PDP), an organic light emitting diode (OLED), and the like, may be used.

The SMPS5may provide power to the display panel4. The SMPS5may be formed by mounting a plurality of electronic components on a printed circuit board6and particularly, may be formed with the transformer100mounted therein according to the above-mentioned embodiments.

The SMPS5may be fixed to a chassis7and be fixedly disposed in the internal space formed by the covers2and8together with the display panel4.

Here, in the transformer100mounted in the SMPS5, the coil50(SeeFIG. 1) is wound parallel to the printed circuit board6. In addition, when viewed from a plane of the printed circuit board6(in a Z direction), the coil50may be wound clockwise or counterclockwise. Therefore, a portion (an upper surface) of the core40may form a magnetic path while being parallel to the back cover8.

Therefore, in the transformer100according to the present embodiment, a path of most of magnetic flux formed between the back cover8and the transformer100in a magnetic field generated by the coil50is formed in the core40, whereby the generation of leakage magnetic flux between the back cover8and the transformer100may be significantly reduced.

Therefore, even in the case that the transformer100according to the present embodiment does not include a separate shielding device (for example, a shield, or the like) provided on an outer portion thereof, vibrations of the back cover8due to interference between the leakage flux of the transformer100and the back cover8formed of a metal material may be prevented.

Therefore, even in the case that the transformer100is mounted in a relatively thin electronic device such as the flat panel display device1, such that the back cover8and the transformer100have a relatively significantly narrow space therebetween; the generation of noise due to vibrations of the back cover8may be prevented.

As set forth above, in the transformer according to the embodiments of the present invention, the winding space of the bobbin is uniformly partitioned into a plurality of spaces, and the respective individual coils are wound in the winding spaces in a uniform dispersal scheme. In addition, the respective individual coils are wound in a shape in which they are stacked.

Therefore, a phenomenon in which the individual coils are wound within the winding part while being inclined toward anyone side or are non-uniformly wound within the winding part while being spaced apart from each other may be prevented. As a result, leakage inductance generated due to non-uniform winding of the coils may be significantly reduced.

In addition, in the transformer according to the embodiments of the present invention, at least one of the primary and secondary coils may have multi-insulated wire. In this case, due to the multi-insulated wire having high insulation properties, insulation properties between the primary and secondary coils may be secured without using a separate insulating layer (for example, the insulating tape).

Therefore, since the insulating tape interposed between the primary and secondary coils according to the related art and a process of attaching the insulating tape may be omitted, manufacturing costs and a manufacturing time may be reduced.

In addition, the transformer according to the embodiment of the present invention may be configured to be appropriate for an automated manufacturing method. More specifically, in the transformer according to the embodiments of the present invention, the insulating tape according to the related art that has been manually interposed while being wound between the coils may be omitted.

In the case according to the related art in which insulating tape is used, a method of winding the coil in the bobbin, manually attaching the insulating tape thereto, and then again winding the coil is repeatedly performed, leading to an increase in manufacturing time and costs.

However, in the transformer according to the embodiments of the present invention, a process of attaching the insulating tape is omitted, whereby the individual coils may be continuously wound in the bobbin while being stacked therein by an automatic winding device. Therefore, a cost and a time required for manufacturing the transformer may be significantly reduced.

In addition, in the transformer according to the embodiments of the present invention, the lead wires of the coils are not disposed within the winding part, but are directly led to the outside of the winding part through the catching groove. Therefore, the coils wound in the winding part are uniformly wound, whereby leakage inductance due to the bending of the coil, or the like, may be significantly reduced.

Further, in the transformer according to the present embodiment, the length of the catching groove is larger than the thickness of the terminal connection part, and the lead wire of the coil is led in a shape in which it crosses the catching groove in the length direction thereof. Therefore, since the lead wire is led while forming an angle less than 45 degrees with respect to the coils wound in the winding part, UL safety standards may be satisfied. Further, a plurality of catching protrusions and double catching protrusions are provided, whereby the disposition direction of the lead wire may be easily changed.

In addition, when the transformer according to the embodiment of the present invention is mounted on the substrate, the coil of the transformer is maintained in a state in which it is wound parallel to the substrate. When the coil is wound parallel to the substrate as described above, interference between leakage magnetic flux generated from the transformer and the outside may be significantly reduced.

Therefore, even in the case that the transformer is mounted in the thin display device, the generation of the interference between leakage magnetic flux generated from the transformer and the back cover of the display device is significantly reduced, whereby a phenomenon in which noise is generated in the display device by the transformer may be prevented. Therefore, the transformer may also be easily used in the thin display device.

The transformer according to the present invention as described above is not limited to the above-mentioned embodiments, but may be variably modified. For example, the case in which the flange part of the bobbin and the partition wall have quadrangular shapes has been described by way of example in the above-mentioned embodiments. However, the present invention is not limited thereto. That is, the flange part of the bobbin and the partition wall may also be circular, an ellipsoidal, or the like, as needed.

In addition, although the case in which the body part of the bobbin has a circular cross section has been described by way of example in the above-mentioned embodiments, the present invention is not limited thereto, but may be variably modified. For example, the body part of the bobbin may also have an ellipsoidal cross section or a polygonal cross section.

Further, although the case in which the terminal connection part is formed on the lower flange part has been described by way of example in the above-mentioned embodiments, the present invention is not limited thereto, but may be variably modified. For example, the terminal connection part may be formed on the upper flange part.

In addition, although the case in which both of the lead groove and the catching groove are formed in the terminal connection part has been described by way of example in the above-mentioned embodiments, the present invention is not limited thereto, but may be variably modified. For example, the catching groove may be only formed, or the lead groove and the catching groove may be independently formed.

Moreover, although the insulating type switching transformer has been described by way of example in the above-mentioned embodiments, the present invention is not limited, but may be widely applied to any transformer, coil component, and electronic device including a plurality of coils wound therein.