Patent Publication Number: US-2013229255-A1

Title: Network transformer module and magnetic element thereof

Description:
RELATED APPLICATIONS 
     This application claims priority to Taiwan Patent Application Serial Number 101107254, filed Mar. 5, 2012, which is herein incorporated by reference. 
     BACKGROUND 
     1. Technical Field 
     The present disclosure relates to a transformer. More particularly, the present disclosure relates to a network transformer module. 
     2. Description of Related Art 
     In recent years, the technology has been developed and progressed in society, the developed products are correspondingly provided for convenience, certainty and economical benefit, and thus the present developed products are more advanced than those such that they can be contributions to the society. 
     For a conventional network transformer, in order to give consideration to both functions of transmitting signals and restraining noise, a transformer and a common mode choke for named “common mode inductor”) are usually configured in the network transformer to perform the functions respectively, and the two devices are connected with each other by a conducting wire. Specifically, in fabrication, after the transformer is fabricated with the conducting wire and completed in a winding process, the same conducting wire is utilized in a winding process for the common mode choke, such that the transformer and the common mode choke are electrically connected with each other by the conducting wire. 
     However, since the two devices are fabricated with the same conducting wire in the winding process, the two devices cannot be fabricated separately, thus causing a minute and complicated fabrication process for the two devices and further resulting in a longer fabrication process for the two devices. Moreover, during the fabrication process, the conducting wire connected between the transformer and the common mode choke tends to be pulled and dragged to be cut off, thus decreasing a yield rate of the products. 
     Therefore, a heretofore unaddressed need exists in the art to address the aforementioned deficiencies and inadequacies. 
     SUMMARY 
     An aspect of the present disclosure is related to a network transformer module. The network transformer module comprises a first magnetic element, a second magnetic element and a connection board. The first magnetic element comprises a first winding set, a first base and a first core. The first winding set is wound around the first core. The first core is disposed on the first base. At least a portion of the first core is relatively higher than a top surface of the first base. The second magnetic element comprises a second winding set, a second base and a second core. The second winding set is wound around the second core. The second core is disposed on the second base. At least a portion of the second core is relatively higher than a top surface of the second base. The first winding set is independent from the second winding set, and the first winding set is not wound around the second core. The connection board is configured or electrically coupling the first winding set with the second winding set. 
     Another aspect of the present disclosure is related a magnetic element. The magnetic element comprises a core, a first conducting wire and a second conducting wire. The first conducting wire is wound around the core. The second conducting wire is wound around the core, in which lengths of the first conducting wire and the second conducting wire are different from each other. 
     Still another aspect of the present disclosure is related to a magnetic element. The magnetic element comprises a core and at least one conducting wire. The core has at least two openings, in which central axes of the openings are nonparallel with each other. The conducting wire is wound around the core. 
     It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the disclosure as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure can be more fully understood by reading the following detailed description of the embodiments, with reference to the accompanying drawings as follows: 
         FIG. 1  is a diagram illustrating a network transformer module according to one embodiment of the present disclosure; 
         FIG. 2  is a diagram illustrating a core assembled by sub-cores according to one embodiment of the present disclosure; 
         FIG. 3  is a diagram illustrating a network transformer module according to another embodiment of the present disclosure; and 
         FIG. 4  is a fragmentary circuit diagram illustrating the network transformer module as shown in  FIG. 1  according to one embodiment of the present disclosure. 
     
    
    
     DESCRIPTION OF THE EMBODIMENTS 
     In the following description, specific details are presented to provide a thorough understanding of the embodiments of the present disclosure. Persons of ordinary skill in the relevant art will recognize, however, that the present disclosure can be practiced without one or more of the specific details, or in combination with other components. Well-known implementations or operations are not shown or described in detail to avoid obscuring aspects of various embodiments of the present disclosure. 
     The terms used in this specification generally have their ordinary meanings in the art and in the specific context where each term is used. The use of examples anywhere in this specification, including examples of any terms discussed herein, is illustrative only, and in no way limits the scope and meaning of the disclosure or of any exemplified term. Likewise, the present disclosure is not limited to various embodiments given in this specification. 
     As used herein, the terms “comprising,” “including,” “having,” “containing,” “involving,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. 
     Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, implementation, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus uses of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, implementation, or characteristics may be combined in any suitable manner in one or more embodiments. 
     In the following description and claims, the terms “coupled” and “connected”, along with their derivatives, may be used. In particular embodiments, “connected” and “coupled” may be used to indicate that two or more elements are in direct physical or electrical contact with each other, or may also mean that two or more elements may not be in direct contact with each other. “Coupled” may still be used to indicate that two or more elements cooperate or interact with each other. 
     The term “in perpendicular to” and “in parallel with” also include “substantially in perpendicular to” and “substantially in parallel with”, respectively, throughout the specification and the claims of the present application. 
       FIG. 1  is a diagram illustrating a network transformer module according to one embodiment of the present disclosure. As shown in  FIG. 1 , the network transformer module  100  includes a plurality of magnetic elements (e.g., a first magnetic element  110 , a second magnetic element  130 , etc.), a connection board  150 , an outer housing  180  and a bottom plate  190 . The magnetic elements are able to be respectively disposed on the connection board  150  by the way of pluggable connection, welding connection or other connections, and then the magnetic elements are assembled with the outer housing  180  and the bottom plate  190  such that they can be packaged together. For convenience of description, the description is exemplarily made as below with the first magnetic element  110  and the second magnetic element  130 , but it is not limiting of the present disclosure. 
     As shown in  FIG. 1 , the first magnetic element  110  and the second magnetic element  130  can be respectively disposed on the connection board  150  by the way of pluggable connection, welding connection or other connections, such that the first magnetic element  110  and the second magnetic element  130  can be electrically coupled to each other through the connection board  150 , and the electrical characteristics of signals transmitted between the first magnetic element  110  and the second magnetic element  130  can thus be consistent. 
     In one embodiment, the first magnetic element  110  can be a transformer or a common mode choke (or common mode inductor), and the second magnetic element  130  can be a corresponding common mode choke or a corresponding transformer in relative to the first magnetic element  110 . For example, when the first magnetic element  110  is the transformer, the second magnetic element  130  is the corresponding common mode choke, and when the first magnetic element  110  is the common mode choke, the second magnetic element  130  is the corresponding transformer. Thus, both functions of transmitting signals and restraining noise can be performed by the first magnetic element  110  and the second magnetic element  130  in the network transformer module  100  at the same time. 
     In one embodiment, the connection board  150  is a circuit board, a lead frame or a substrate, and the connection board  150  are other supports for the first magnetic element  110  and the second magnetic element  130  to be disposed such that they can be electrically coupled to each other, and thus it is not limiting of the present disclosure. 
     In the present embodiment, the first magnetic element  110  includes a first winding set  112  and a first core  114  and the first winding set  112  is wound around the first core  114 , and the second magnetic element  130  includes a second winding set  132  and a second core  134  and the second winding set  132  is wound around the second core  134 , in which the first winding set  112  is independent from the second winding set  132  and not directly coupled with the second winding set  132 , and the first winding set  112  is not wound around the second core  134 , and the second winding set  132  is not wound around the first core  114 . 
     In addition, as an embodiment, the connection board  150  is configured for electrically coupling the first winding set  112  with the second winding set  132 . For example, the first magnetic element  110  further includes a first base  116  and a pin  118 , in which the first winding set  112  and the first core  114  are disposed above the first base  116 , the first core  114  is disposed on the first base  116 , and at least a portion of the first core  114  is relatively higher than a top surface (i.e., the other surface in relative to the surface on which the pin  118  is disposed, of the first base  116 ) of the first base  116 . The pin  118  is disposed below the first base  116  and coupled to the first winding set  112 , such that when the pin  118  is disposed on the connection board  150  (for example, the pin  118  passes through a hole  155  of the connection board  150 ), the first winding set  112  can further be electrically coupled to the connection board  150  through the pin  118 . 
     Similarly, as another embodiment, the second magnetic element  130  her includes a second base  136  and a pin  138 , in which the second winding  132  and the second core  134  are disposed above the second base  136 , the second core  134  is disposed on the second base  136 , and at least a portion of the second core  134  is relatively higher than a top surface (i.e., the other surface in relative to the surface on which the pin  138  is disposed, of the second base  136 ) of the second base  136 . The pin  138  is disposed below the second base  136  and coupled to the second winding set  132 , such that when the pin  138  is disposed on the connection board  150  (for example, the pin  138  passes through a hole  156  of the connection board  150 ), the second winding set  132  can further be electrically coupled to the connection board  150  through the pin  138 . 
     The bases  116  and  136  are provided for the cores  114  and  134 , respectively, and therefore not only the first winding set  112  and the second winding set  132  can be effectively supported, but also the connection strength of the connection board  150  connecting with the first magnetic element  110  and the second magnetic element  130  can be enhanced to further increase the yield rate of the products and provide stable electrical characteristics. 
     Furthermore, as an embodiment, the first winding set  112  and the second winding set  132  also directly pass through the holes (e.g., the holes  155  and  156 ) of the connection board  150 , and thus production costs can be reduced significantly. 
     On the other hand, a wire of the first winding set  112  may be the same as or different from a wire of the second winding set  132  in diameter or length, and persons of ordinary skill in the art can only select an appropriate diameter of a wire according to practical needs. When the diameters or lengths of the wires of the first winding set  112  and the second winding set  132  are changed, or even the diameter or length of the wire of the first winding set  112  is different from the diameter or length of the wire of the second winding set  132 , the insertion loss can be correspondingly modified and improved. 
     The first winding set  112  and the second winding set  132  are electrically coupled to each other through the connection board  150 , such that the first magnetic element  110  and the second magnetic element  130  need not be connected with each other by the conducting wire which has a length that is difficult to be controlled, for avoiding the issue that the two magnetic elements are fabricated with the same conducting wire in a winding process and thus cannot be manufactured separately, so as to shorten the process time for achieving the automated production, and also to prevent the conducting wire connected between the two magnetic elements from being cut off. 
     In one embodiment, the first core  114  or the second core  134  has N openings for the winding set to be wound, in which N is a positive integer. For example, as shown in  FIG. 1 , the first core  114  has two openings  123 ,  125  for the first winding set  112  to be wound, and the second core  134  has two openings  143 ,  145  for the second winding set  132  to be wound. In practice, the number of openings of the first core  114  and the second core  134  can be increased appropriately, and when the number of openings of the core is increased, the strength of magnetic field can thus be enhanced effectively. 
     In another embodiment, the first core  114  or the second core  134  has at least two openings, and central axes of the openings are nonparallel with each other. For example, central axes of the openings  123 ,  125  of the first core  114  are nonparallel with each other, or central axes of the openings  143 ,  145  of the second core  134  are nonparallel with each other. In other words, the central axes of the openings of the same core can be in parallel with each other or nonparallel with each other, and the central axes of the openings of different cores can be in parallel with each other or nonparallel with each other as well. 
     As mentioned above, different numbers, sizes or shapes of openings of the core can be designed and used for the winding set according to practical needs, by persons of ordinary skill in the art, and thus  FIG. 1  is not limiting of the present disclosure. 
     In one embodiment, the first core  114  or the second core  134  may further include M sub-cores, and M is a positive integer which is greater than 1. In another embodiment, a shape of any one of the sub-cores can be the E shape, the P shape, the I shape, the C shape, the H shape, the U shape, the L shape, or the ring shape. For example,  FIG. 2  is a diagram illustrating a core assembled by sub-cores according to one embodiment of the present disclosure, in which a core  200  is assembled by two sub-cores  202 ,  204 . 
     Notably, the number and shape of the sub-cores as shown in  FIG. 2  are merely illustrative but not limiting of the present disclosure, and the number and shape of the sub-cores and the manner of assembling the same can be designed and selected according to practical needs by persons of ordinary skill in the art, in order to implement the first core  114  or the second core  134 . 
     In one embodiment, the first winding set  112  or the second winding set  132  further includes P conducting wires, and P is a positive integer. For example, the first winding set  112  or the second winding set  132 , as shown in  FIG. 1 , is fabricated with a single conducting wire. 
     In addition, when the first winding set  112  or the second winding set  132  includes P conducting wires (i.e., when P is the positive integer of 2 or greater than 2), lengths of at least two of the conducting wires of the first winding set  112  or the second winding set  132  may be different from each other; in other words, at least two of the conducting wires can be configured to have different lengths. In another embodiment, the lengths of all of the conducting wires of the first winding set  112  or the second winding set  132  are different from each other. When the lengths of at least two of the conducting wires are different from each other, the insertion loss can be and effectively improved. 
     One specific embodiment is shown in  FIG. 3  which is a diagram illustrating a network transformer module according to another embodiment of the present disclosure. In the network transformer module  300  of the present embodiment, a first winding set  320  includes a first conducting wire  322  and a second conducting wire  324 , the first conducting wire  322  and the second conducting wire  324  are wound around a first core  314 , a second winding set  340  includes a third conducting wire  342  and a fourth conducting wire  344 , and the third conducting wire  342  and the fourth conducting wire  344  are wound around a second core  334 , in which lengths of the first conducting wire  322  and the second conducting wire  324  are different from each other, or lengths of the third conducting wire  342  and the fourth conducting wire  344  are different from each other. In another embodiment, the lengths of the first conducting wire  322 , the second conducting wire  324 , the third conducting wire  342  and the fourth conducting wire  344  can be selectively designed to be all the same, partially the same or different from each other. The corresponding lengths of the aforementioned conducting wires can be designed according to practical needs by persons of ordinary skill in the art, and thus it is not limiting of the present disclosure. 
     The features of the magnetic elements in the embodiments mentioned above can be formed individually or formed together. Specifically, the first core  114  or the second core  134  may have a plurality of openings, and the first core  114  or the second core  134  may further include a plurality of sub-cores. Therefore, the features in the respective embodiments are individually described for convenience of description, all of the embodiments can be selectively collocated to implement the magnetic elements in the present disclosure, and thus the respective embodiments are not intended to be limiting of the present disclosure. 
       FIG. 4  is a fragmentary circuit diagram illustrating the network transformer module as shown in  FIG. 1  according to one embodiment of the present disclosure. As shown in  FIG. 4 , a first magnetic element  410  (e.g., a transformer) and a second magnetic element  430  (e.g., a common mode choke) are not directly coupled to each other but are electrically coupled to a connection board  450  respectively by the way of pluggable connection, welding connection or other connections, such that first magnetic element  410  and the second magnetic element  430  are electrically coupled to each other through the connection board  450 . 
     Given the foregoing embodiments of the present disclosure, it is known that the network transformer module and the magnetic element therein not only simultaneously realize both functions of transmitting signals and restraining noise, but also make the electrical characteristics of signals transmitted between different magnetic elements consistent. In addition, two magnetic elements need not be connected with each other via the conducting wire and can be manufactured separately, so as to shorten the process time for achieving the automated production, and also to prevent the conducting wire connected between the two magnetic elements from being cut off. Furthermore, by changing the diameters or lengths of the wires of the winding set in the magnetic element, the insertion loss can be correspondingly modified and improved. 
     As is understood by a person skilled in the art, the foregoing embodiments of the present disclosure are illustrative of the present disclosure rather than limiting of the present disclosure. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.