Patent Publication Number: US-2016233020-A1

Title: Transformer

Description:
TECHNICAL FIELD 
     The present disclosure relates to a transformer, and more particularly to a high-voltage transformer utilizing a honeycomb winding so as to be automatically manufactured. 
     BACKGROUND OF THE DISCLOSURE 
     A transformer plays a very important role in lots types of electric devices or electric apparatuses. That is, the transformer is considered as a necessary and critical component. With growing of the applications of the high-voltage apparatuses, a high-voltage transformer is going to be the most popular product. 
     Please refer to  FIG. 1 .  FIG. 1  schematically illustrates the structure of a conventional transformer of prior art. As shown in  FIG. 1 , a magnetic core assembly  10  of a conventional transformer  1  is penetrated through a left bobbin  11  and a right bobbin  12 . A primary winding  13  is wound on the right bobbin  12 , and a secondary winding  14  is wound on the primary winding  13 . In this conventional transformer  1 , since the secondary winding  14  is wound on the primary winding  13 , it is not simple for the secondary winding  14  to be arranged due to the intervals of the primary winding  13 . In addition, a tape has to be wrapped around the primary winding  13  for meeting the safety requirements between the primary winding  13  and the secondary winding  14 , such that the heat dissipation of the primary winding  13  is reduced. Moreover, if the tape or the winding is damaged, there still exists a risk of safety in this kind of winding manner and structure. 
     Please refer to  FIG. 2 .  FIG. 2  schematically illustrates the structure of another conventional transformer of prior art. As shown in FIG.  2 , a magnetic core assembly  20  of a conventional transformer  2  is penetrated through a left bobbin  21  and a right bobbin  22 . A primary winding  23  is respectively wound on the left bobbin  21  and the right bobbin  22 , and a secondary winding  24  is wound on the right bobbin  22 . In this conventional transformer  2 , since the secondary winding  24  and the primary winding  23  are directly wound on the right bobbin  22  but not wound on one of any winding, the arrangement issue caused by the intervals of winding is avoided, and the heat dissipation is enhanced. However, a larger leakage inductance is produced in this kind of conventional transformer  2 , thereby reducing the product performance. Since a two-time winding action is necessary to wind the primary winding  23  on the left bobbin  21  and the right bobbin  22 , the manufacturing process is complicated and difficult. 
     There is a need of providing a transformer to obviate the drawbacks encountered from the prior art. 
     SUMMARY OF THE DISCLOSURE 
     It is an object of the present disclosure to provide a transformer in order to overcome the above-mentioned drawbacks encountered by the prior arts. 
     The present disclosure provides a transformer. By utilizing the honeycomb winding and the spiral winding coils as windings and utilizing the air as main insulation and isolation, the transformer achieves the advantages of being applied to be automatically wound and assembled, and enhancing the heat dissipation and safety. 
     The present disclosure also provides a transformer. Via the latches mechanism, the distances between the honeycomb winding and the spiral winding coils can be easily kept, so that the product properties can be ensured. Meanwhile, since the structure of the transformer is formed in manner of sandwich winding, the leakage inductance is effectively reduced and the distances between the honeycomb winding and the spiral winding coils are easy to be adjusted for designing the withstand voltage characteristics of the transformer. 
     In accordance with an aspect of the present disclosure, there is provided a transformer. The transformer includes a bobbin, a honeycomb winding, a first spiral winding coil, a first lateral plate and a magnetic core assembly. The bobbin has a winding base and a first extending portion extended from the winding base. The honeycomb winding is wound on the winding base. The first spiral winding coil is disposed on the first extending portion. The first lateral plate is disposed between the first spiral winding coil and the bobbin. The first lateral plate has a first ring-shaped protruding portion sleeved on the first extending portion. A channel is defined by the first ring-shaped protruding portion and the first extending portion. The magnetic core assembly includes two magnetic cores. Each magnetic core has a first lateral post and a second lateral post. The first lateral posts of the two magnetic cores are disposed opposite to each other. The second lateral posts of the two magnetic cores are disposed opposite to each other. Each of the first lateral posts is penetrated through the channel. 
     In accordance with another aspect of the present disclosure, there is provided a transformer. The transformer includes a bobbin, a honeycomb winding, a first spiral winding coil, a second spiral winding coil and a magnetic core assembly. The bobbin has a winding base, a first extending portion and a second extending portion. The first extending portion and the second extending portion are relatively extended from two sides of the winding base. A channel is defined by the first extending portion and the second extending portion. The honeycomb winding is wound on the winding base. The first spiral winding coil is disposed on the first extending portion. The second spiral winding coil is disposed on the second extending portion. The magnetic core assembly includes two magnetic cores. Each magnetic core has a first lateral post and a second lateral post. The first lateral posts of the two magnetic cores are disposed opposite to each other. The second lateral posts of the two magnetic cores are disposed opposite to each other. Each of the first lateral posts is penetrated through the channel. 
     The above contents of the present disclosure will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  schematically illustrates the structure of a conventional transformer of prior art; 
         FIG. 2  schematically illustrates the structure of another conventional transformer of prior art; 
         FIG. 3  schematically illustrates the exploded view of a transformer according to an embodiment of the present disclosure; 
         FIG. 4  schematically illustrates the combined structure of the transformer shown in  FIG. 3 ; 
         FIG. 5  schematically illustrates the distance between the honeycomb winding and the first spiral winding coil and the distance between the honeycomb winding and the second spiral winding coil according to an embodiment of the present disclosure; and 
         FIG. 6  schematically illustrates the exploded view of a transformer according to another embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present disclosure will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this disclosure are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed. 
     Please refer to  FIG. 3  and  FIG. 4 .  FIG. 3  schematically illustrates the exploded view of a transformer according to an embodiment of the present disclosure.  FIG. 4  schematically illustrates the combined structure of the transformer shown in  FIG. 3 . As shown in  FIG. 3  and  FIG. 4 , a transformer  5  of the present disclosure at least includes a bobbin  50 , a honeycomb winding  51 , a first spiral winding coil  52 , a first lateral plate  53  and a magnetic core assembly  54 . The bobbin  50  has a winding base  500  and a first extending portion  501 . The honeycomb winding  51  is wound on the winding base  500 . The first spiral winding coil  52  is disposed on the first extending portion  501 . The first lateral plate  53  is disposed between the first spiral winding coil  52  and the bobbin  50 . The first lateral plate  53  has a first ring-shaped protruding portion  531  sleeved on the first extending portion  501 . A channel T is defined by the first ring-shaped protruding portion  531  and the first extending portion  501 . The magnetic core assembly  54  includes two magnetic cores  540 . The two magnetic cores  540  have similar exteriors and structures. Each magnetic core  540  has a first lateral post  5401  and a second lateral post  5402 . The first lateral posts  5401  of the two magnetic cores  540  are disposed opposite to each other, the second lateral posts  5402  of the two magnetic cores  540  are disposed opposite to each other, and each of the first lateral posts  5401  is penetrated through the channel T, so that the transformer  5  is structured. In this embodiment, the magnetic core assembly  54  is a U-U core assembly, but not limited herein. Under this circumstance, the air is utilized as the main insulation and isolation between the honeycomb winding and the first spiral winding coil, and further the first lateral plate is utilized for increasing the creepage distance, so that the safety distance is increased, the heat dissipation is enhanced, and the safety is significantly enhanced. 
     In some embodiments, the bobbin  50  further has a second extending portion  502 , and the second extending portion  502  and the first extending portion  501  are relatively extended from the two sides of the winding base  500 . In addition, the transformer  5  further includes a second spiral winding coil  55 . The second spiral winding coil  55  is disposed on the second extending portion  502 . Certainly, the transformer  5  may also include a second lateral plate  56 . The second lateral plate  56  is disposed between the second spiral winding coil  55  and the bobbin  50 . The second lateral plate  56  has a second ring-shaped protruding portion  561  sleeved on the second extending portion  502 . The channel T is defined by the second ring-shaped protruding portion  561 , the second extending portion  502 , the first ring-shaped protruding portion  531  and the first extending portion  501 . Under this circumstance, the first spiral winding coil  52  is substantially sleeved on the first ring-shaped protruding portion  531 , and the second spiral winding coil  55  is substantially sleeved on the second ring-shaped protruding portion  561 . 
     Please refer to  FIG. 5 .  FIG. 5  schematically illustrates the distance between the honeycomb winding and the first spiral winding coil and the distance between the honeycomb winding and the second spiral winding coil according to an embodiment of the present disclosure. As shown in  FIG. 5 , interval distances D are between the honeycomb winding  51  and the first spiral winding coil  52  and between the honeycomb winding  51  and the second spiral winding coil  55 . The interval distances D may be adjusted for meeting the practical demands of transformer design. For example, when the interval distances D are reduced, the leakage inductance of the transformer  5  is also reduced. In some embodiments, the honeycomb winding  51  is the secondary winding, and the first spiral winding coil  52  and the second spiral winding coil  55  are the primary winding, but not limited thereto. As a result, since the structure of the transformer in this embodiment is formed in manner of sandwich winding, the leakage inductance is effectively reduced and the distances between the honeycomb winding and the spiral winding coils are simply adjusted for designing the withstand voltage characteristics of the transformer. 
     Please refer to  FIG. 3  and  FIG. 4  again. In some embodiments, the first ring-shaped protruding portion  531  of the first lateral plate  53  and the second ring-shaped protruding portion  561  of the second lateral plate  56  of the transformer  5  of the present disclosure have at least a first latch  532  and at least a second latch for auxiliary positioning the first spiral winding coil  52  and the second spiral winding coil  55 , respectively. It should be noted that since the first lateral plate  53  and the second lateral plate  56  have the similar exteriors and structures, the second latch is omitted on the drawings. However, the second latch can be indisputably deduced through referring to the first latch  532 . Furthermore, the bobbin  50  of the transformer  5  further includes at least a base latch  503 . The base latch  503  is disposed on the edge of the winding base  500  for auxiliary positioning the honeycomb winding  51 . In brief, via the latches mechanism, the distances between the honeycomb winding and the spiral winding coils can be easily kept, so that the product properties can be ensured. The transformer  5  is applied to be automatically wound and assembled, thereby implementing the automatic manufacture. 
     In some embodiments, the diameter of the wire of the honeycomb winding  51  is preferably 0.23 millimeters, and the amount of the turns of the honeycomb winding  51  is at least 2000. Since the honeycomb winding  51  can be easily wound as pillar-shaped, the volume is significantly reduced. As a result, the transformer  5  of the present disclosure can be applied to high withstand voltage (e.g. more than 7500 volts). Compared with the withstand voltage between 2000 volts and 5000 volts of the conventional transformer, the withstand voltage characteristics of the transformer  5  of the present disclosure is significantly enhanced. 
     Please refer to  FIG. 6 .  FIG. 6  schematically illustrates the exploded view of a transformer according to another embodiment of the present disclosure. As shown in  FIG. 6 , there is also provided a transformer  6 . The transformer  6  includes a bobbin  60 , a honeycomb winding  61 , a first spiral winding coil  62 , a second spiral winding coil  63  and a magnetic core assembly  64 . The bobbin  60  has a winding base  600 , a first extending portion  601  and a second extending portion  602 . The first extending portion  601  and the second extending portion  602  are relatively extended from the two sides of the winding base  600 . A channel T is defined by the first extending portion  601  and the second extending portion  602 . The honeycomb winding  61  is wound on the winding base  600 . The first spiral winding coil  62  is disposed on the first extending portion  601 . The second spiral winding coil  63  is disposed on the second extending portion  602 . The magnetic core assembly  64  includes two magnetic cores  640 . Each magnetic core  640  has a first lateral post  6401  and a second lateral post  6402 . The first lateral posts  6401  of the two magnetic cores  640  are disposed opposite to each other. The second lateral posts  6402  of the two magnetic cores  640  are disposed opposite to each other. Each of the first lateral posts  6401  is penetrated through the channel T. Compared with the transformer  5  of the embodiment mentioned above, the transformer  6  of this embodiment is a transformer with a plate-less bobbin, so that the transformer of the present disclosure are applied to the products met different demands. 
     From the above description, the present disclosure provides a transformer. By utilizing the honeycomb winding and the spiral winding coils, and by utilizing the air as main insulation and isolation, the transformer achieves the advantages of being applied to be automatically wound and assembled, and enhancing the heat dissipation and safety. On the other hand, via the latches mechanism, the distances between the honeycomb winding and the spiral winding coils can be easily kept, so that the product properties can be ensured. Meanwhile, since the structure of the transformer is formed in manner of sandwich winding, the leakage inductance is effectively reduced and the distances between the honeycomb winding and the spiral winding coils are easy to be adjusted for designing the withstand voltage characteristics of the transformer. 
     While the disclosure has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.