Patent Description:
Electrical components such as transformers and inductors are commonly used in switch-mode power supplies and typically have windings formed of various types of wires and coils. Spacing between the windings within the electrical component is often caused, for example, by one or more spacers which mechanically separate and/or support the windings.

<CIT>, <CIT> and <CIT> each disclose a switch-mode power supply in accordance with the preamble of claim <NUM>.

<CIT> discloses spacer members for electric coils of an electrical induction apparatus, wherein a space member provides both radial and axial spacing of the coils.

<CIT> discloses a known switch-mode DC-DC power converter.

According to one aspect of the present disclosure, a switch-mode power supply as recited in independent claim <NUM> is disclosed. Further aspect of the switch-mode power supply are disclosed in dependent claims <NUM>-<NUM>.

According to another aspect of the present disclosure, a method of adjusting a space between adjacent windings (<NUM>) of an electrical component (<NUM>) of a power circuit of a switch-mode power supply as recited in independent claim <NUM> is disclosed. Further aspect of the method are disclosed in dependent claims <NUM>-<NUM>.

Further aspects and areas of applicability will become apparent from the description provided herein. It should be understood that various aspects of this disclosure may be implemented individually or in combination with one or more other aspects. It should also be understood that the description and specific examples herein are intended for purposes of illustration only and are not intended to limit the scope of the claims.

The drawings described herein are for illustrative purposes only of selected embodiments not all possible implementations, and are not intended to limit the scope of the claims.

Corresponding reference numerals indicate corresponding parts or features throughout the several views of the drawings.

A transformer according to the invention is illustrated in <FIG> and indicated generally by reference number <NUM>. The transformer <NUM> includes a plurality of windings <NUM> (e.g., primary and secondary windings) and a core <NUM> which magnetically couples the windings <NUM>. The transformer <NUM> also includes an adjustable spacer <NUM> having an adjustable thickness, which serves to mechanically separate and support the windings <NUM>.

The adjustable spacer <NUM> includes an adjustment mechanism <NUM> which permits the thickness of the adjustable spacer <NUM> to be adjusted within a range of thicknesses (as limited by the adjustment mechanism <NUM>, etc.). Because the thickness of the adjustable spacer <NUM> may be adjusted, the adjustable spacer <NUM> is suitable for use with various electrical components (e.g., transformers, inductors, etc.) that have the same core size, but different air gap sizes, configurations of windings (e.g., windings <NUM>), number of windings (e.g., windings <NUM>), material tolerances, etc. In particular, one spacer (e.g., adjustable spacer <NUM>) may be included in electrical components of a particular core size, where each component requires a different thickness of spacer, rather than using multiple spacers or spacers of different thicknesses to achieve the desired thickness. As can be appreciated, a spacer with an adjustable thickness allows for one part number to be used with a core size family (e.g., electrical components of a given core size) as the adjustable spacer <NUM> accommodates a range of thicknesses needed for the different electrical components. Additionally, adjustable spacer <NUM> may be sized and shaped for use with cores of different sizes and/or shapes.

In some embodiments, in addition to adjusting the thickness of the adjustable spacer <NUM>, the adjustment mechanism <NUM> also permits the adjustable spacer <NUM> to be separated into a first segment <NUM> and a second segment <NUM>, to enable the first segment <NUM> to be detachably coupled to the second segment <NUM>. The disks <NUM> and <NUM> are also referred to herein as disks. As shown in the exploded view of <FIG>, the first disk <NUM> of the adjustable spacer <NUM> is detached from the second disk <NUM> of the adjustable spacer <NUM>. In some embodiments, the first disk <NUM> and the second disk <NUM> can move relative to the other, so as to adjust in thickness, and are unable to be separated.

As shown in <FIG>, the adjustable spacer <NUM> is positioned between windings <NUM> within the transformer <NUM>. In the illustrated embodiment, the adjustable spacer <NUM> is centrally positioned within the transformer <NUM>. By doing so, the adjustable spacer <NUM> is able to position the windings <NUM> away from the air gap of the transformer <NUM>. In this manner, fringing flux associated with the transformer <NUM> may be reduced (e.g., as compared to a transformer including a spacer of a given thickness, etc.).

In the embodiment, the adjustment mechanism <NUM> is a screw-type adjustment mechanism and includes a matching pair of threads (i.e., threads <NUM> and threads <NUM>). Threads <NUM> are included on the first disk <NUM> of the adjustable spacer <NUM> and threads <NUM> are included on the second disk <NUM>. As shown, the pair of threads <NUM>, <NUM> are a matching pair of threads (e.g., threads <NUM> are internal threads and threads <NUM> are external threads), such that the disks <NUM>, <NUM> of the adjustable spacer <NUM> may be screwed together and/or unscrewed. By screwing and/or unscrewing the adjustable spacer <NUM>, the thickness of the adjustable spacer <NUM> may be altered, as described in more detail below. While the exemplary embodiment illustrates a screw- type adjustment mechanism that includes threads, other types of adjustment mechanisms are contemplated (e.g., an adjustment mechanism including springs, steps, wedges, etc.) for altering the thickness of the adjustable spacer <NUM>.

The adjustable spacer <NUM> also includes a surface <NUM> on the first disk <NUM> and a surface <NUM> on the second disk <NUM>. Surfaces <NUM> and <NUM> are generally planar and may interface with the windings <NUM>. In particular, when the adjustable spacer <NUM> is adjusted to a desired thickness, surface <NUM> and surface <NUM> may both contact the windings <NUM>. Contact of the surfaces <NUM>, <NUM> with the windings <NUM> enables the adjustable spacer <NUM> to secure the windings <NUM> within the transformer <NUM> in a manner that ensures the compactness of the components within the transformer <NUM> and reduces fringing flux by positioning the windings away from the air gap of the transformer <NUM>.

<FIG> illustrate the adjustable spacer <NUM> as adjusted to a first thickness and to a second thickness. As shown in <FIG>, the adjustable spacer <NUM> is in a fully closed state. In the fully closed state, the adjustable spacer <NUM> is at a narrowest thickness such that threads <NUM> of first disk <NUM> are fully engaged with threads <NUM> of second disk <NUM>. In the illustrated embodiment, in the fully closed stated, only the first disk <NUM> of the adjustable spacer <NUM> is in contact with the windings <NUM> (e.g., both of the disks <NUM>, <NUM> are not in contact with the windings <NUM>). When only one of the disks of the adjustable spacer <NUM> (e.g., either first disk <NUM> or second disk <NUM>) is in contact with the windings <NUM>, windings <NUM> are permitted to move relative to the core <NUM>.

To secure the windings <NUM> within the transformer <NUM> (and prevent damage to the windings <NUM> and/or the core <NUM>), the thickness of the adjustable spacer <NUM> may be altered or adjusted. In particular, the adjustable spacer <NUM> may be adjusted to an increased thickness by rotating second disk <NUM> with respect to disk <NUM>, as indicated by arrow <NUM>. As second disk <NUM> is rotated, second disk <NUM> moves outward along a central axis <NUM> of the transformer <NUM>, based on the configuration of threads <NUM> and <NUM>. After rotation of the second disk <NUM>, threads <NUM> of the first disk <NUM> are partially engaged with the threads <NUM> of the second disk <NUM>, such that the adjustable spacer <NUM> is in a partially opened state. In the partially opened state, as shown in <FIG>, both disks <NUM>, <NUM> are in contact with the windings <NUM> via surface <NUM> and surface <NUM>. When both disks of the adjustable spacer <NUM> engage with the windings <NUM>, the windings <NUM> are secured in a manner that maintains the desired spacing and positioning of the components of the transformer <NUM> (e.g., compactness of the components, positioning the windings away from the air gap, etc.).

The adjustable spacer <NUM> also includes an opening <NUM> through the center of the adjustable spacer <NUM>. The opening <NUM> permits passage of the core <NUM> (e.g., a post of the core <NUM>) through the adjustable spacer <NUM>. In the illustrated embodiment, threads <NUM> and <NUM> are generally positioned around the opening <NUM> (e.g., threads <NUM> are positioned on a shaft defining opening <NUM>).

As best shown in <FIG>, the adjustable spacer <NUM> optionally includes a plurality of notches <NUM> at the edge of surfaces <NUM>, <NUM>. Notches <NUM> facilitate grip of the adjustable spacer <NUM>, for example, during rotation of the first disk <NUM> with respect to the second disk <NUM> (e.g., while adjusting the thickness of the adjustable spacer <NUM>). Notches <NUM> may be rounded, squared, etc. or any other shape that provides an increased ability to grasp and/or rotate the adjustable spacer <NUM>.

<FIG> illustrates an example of an adjustable spacer <NUM> not falling within the scope of the claims including a spring-type adjustment mechanism having at least one spring <NUM>. Similar to adjustable spacer <NUM>, the adjustable spacer <NUM> is suitable for use in electrical components (e.g., transformers, inductors, etc.) including transformer <NUM>, for example, to separate and/or provide space between windings <NUM> included the transformer <NUM>. Adjustable spacer <NUM> includes a first segment or disk <NUM> and a second segment or disk <NUM>. In the illustrated embodiment, the adjustable spacer <NUM> includes two springs <NUM>, with one spring <NUM> positioned on the first disk <NUM> and the other spring <NUM> positioned on the second disk <NUM>. While each segment is depicted as including one spring, each segment of adjustable spacer <NUM> may include a greater or lesser number of springs. The springs <NUM> are equally spaced about the adjustable spacer <NUM> to bias the adjustable spacer <NUM> to a uniform thickness (e.g., such that disk <NUM> is parallel to disk <NUM>). As illustrated, springs <NUM> are cantilever springs, although other types of springs may be suitable (e.g., coil spring, etc.) for inclusion within the spring-type adjustment mechanism of the adjustable spacer <NUM>.

Adjustable spacer <NUM> also includes pins <NUM> and corresponding holes <NUM> for alignment of the first disk <NUM> and the second disk <NUM>. In particular, the first disk <NUM> includes pin 432a which is received by hole 434a of second disk <NUM> and pin 432b which is received by hole 434b of second disk <NUM>. Second disk <NUM> likewise includes a pin (not shown) which is received in hole 434c of first disk <NUM> and a pin (not shown) which is received in hole 434d of first disk <NUM>. While each segment includes two pins, a greater or lesser number of pins (and corresponding holes) may be included in each segment of the adjustable spacer <NUM>. As illustrated in <FIG>, each disk <NUM>, <NUM> include the same configuration of springs <NUM>, pins <NUM> and holes <NUM>, such that the first disk <NUM> of adjustable spacer <NUM> is identical to the second disk <NUM> of adjustable spacer <NUM>. As can be appreciated, implementing the same configuration for the first disk <NUM> and the second disk <NUM> of the adjustable spacer <NUM> provides simplified manufacturing.

Due to the inclusion of springs <NUM>, adjustable spacer <NUM> is biased to a largest (e.g., widest) thickness. To reduce the thickness of adjustable spacer <NUM>, the adjustable spacer <NUM> is compressed as desired. In particular, when included in a transformer (e.g., transformer <NUM>), windings <NUM> compress the springs <NUM> of the adjustable spacer <NUM>. The compression of the springs <NUM> of the adjustable spacer <NUM> is based at least in part on the available space within the winding area of the transformer <NUM> (e.g., within an area defined by the core <NUM>, etc.). In connection therewith, the inclusion of springs <NUM> bias the windings <NUM> of the transformer <NUM> towards the core <NUM>, such that the windings <NUM> are positioned away from the air gap (e.g., to reduce fringing flux, etc.). Additionally, the adjustable spacer <NUM> further includes a plurality of stoppers <NUM> to ensure that pins <NUM> do not interfere with the windings <NUM> when the adjustable spacer <NUM> is compressed (e.g., stoppers <NUM> prevent pins <NUM> from fully passing through the disks <NUM>, <NUM>). As can be appreciated, in embodiments where springs <NUM> are cantilever springs, adjustable spacer <NUM> is formed of a material that permits springs <NUM> to flex and compress as desired (e.g., plastic, etc.).

<FIG> illustrates another embodiment of an adjustable spacer <NUM> that includes a step-type adjustment mechanism having at least one protruding step <NUM> and at least one recessed step <NUM>. Similar to adjustable spacer <NUM>, the adjustable spacer <NUM> is suitable for use in electrical components (e.g., transformers, inductors, etc.) including transformer <NUM>, for example, to separate and/or provide space between windings <NUM> included the transformer <NUM>. Adjustable spacer <NUM> includes a first segment or disk <NUM> and a second segment or disk <NUM>. As shown in the illustrated embodiment, the first disk <NUM> includes a plurality of protruding steps <NUM> which are equally spaced about the first disk <NUM>. In particular, first disk <NUM> includes four protruding steps <NUM> which are positioned at an outer edge of first disk <NUM>, although a greater or lesser number of steps <NUM> may be included. The second disk <NUM> includes a plurality of corresponding recessed steps <NUM> of varying depths which are configured to receive the protruding steps <NUM> of first disk <NUM>. In particular, second disk <NUM> includes a set of recessed steps 540a of a first depth, a set of recessed steps 540b of a second depth, and a set of recessed steps 540c of a third depth. Each set of recessed steps <NUM> (e.g., recessed steps 540a of the first depth) includes a number of steps corresponding to number of protruding steps <NUM> of the first disk <NUM>, such that each of the protruding steps <NUM> of the first disk <NUM> may be received within only one set of recessed steps <NUM> of the second disk <NUM> (e.g., received within recessed steps 540a of the first depth) at a given time. While only three sets of recessed steps <NUM> of varying depths are depicted in the exemplary embodiment, a greater or lesser number of sets may be included to provide a differing range of thicknesses of the adjustable spacer <NUM>.

In the illustrated embodiment, the protruding steps <NUM> of the first disk <NUM> are aligned with the first set of recessed steps 540a. When the first disk <NUM> is coupled to the second disk <NUM> by inserting the protruding steps <NUM> into the recessed steps 540a, the thickness of the adjustable spacer <NUM> is at a narrowest thickness (e.g., based on the depth of the recessed steps 540a). To adjust (e.g., increase) the thickness of the adjustable spacer <NUM>, the first disk <NUM> may be rotated such that the protruding steps <NUM> align with and are inserted into the recessed steps 540b of the second disk <NUM>, which have a smaller depth than recessed steps 540a. In this way, when the protruding steps <NUM> are inserted into the recessed steps 540b of the second disk <NUM>, the thickness of the adjustable spacer <NUM> is increased as the recessed steps 540b are of a shallower depth than recessed steps 540a. Adjustable spacer <NUM> is at a greatest thickness when the protruding steps <NUM> of the first disk <NUM> are inserted into the recessed steps 540c of the second disk <NUM>, as these recessed steps have the smallest depth. Alternatively, rather than including one set of protruding steps of a given height and multiple sets of recessed steps of varying depths, adjustable spacer <NUM> may alternatively include multiple sets of protruding steps of varying heights and one set of recessed steps of a given depth. As compared to the screw-type adjustment mechanism <NUM> of adjustable spacer <NUM> and the spring-type adjustment mechanism of the adjustable spacer <NUM> which both provide a continuous transition along the range of thicknesses of the adjustable spacer, the adjustment mechanism of adjustable spacer <NUM> instead provides a series of stepped or graduated thicknesses for the adjustable spacer (e.g., three distinct thicknesses).

<FIG> illustrate another example of an adjustable spacer <NUM> not falling within the scope of the claims including a wedge-type adjustment mechanism that includes a fastener, such as a cable tie <NUM>. Similar to adjustable spacers <NUM>, <NUM> and <NUM>, the adjustable spacer <NUM> is suitable for use in electrical components (e.g., transformers, inductors, etc.) including transformer <NUM>, for example, to separate and/or provide space between windings <NUM> included the transformer <NUM>. Adjustable spacer <NUM> includes a first segment or disk <NUM> and a second segment or disk <NUM>, each of which define a central opening <NUM>. The first disk <NUM> includes a lip <NUM> at the opening <NUM> and the second disk <NUM> also includes a lip <NUM> at the opening <NUM>. In the illustrated embodiment, the first disk <NUM> includes an angled surface <NUM>, which slopes down from the lip <NUM> towards an outer edge of the first disk <NUM>. The second disk <NUM> also includes an angled surface <NUM>, which slopes down from the lip <NUM> towards an outer edge of the second disk <NUM>. In the illustrated embodiment, both disk <NUM> and <NUM> have the same configuration of lips <NUM>, <NUM> and angled surfaces <NUM>, <NUM>, such that the first disk <NUM> of adjustable spacer <NUM> is identical to the second disk <NUM> of adjustable spacer <NUM>. As can be appreciated, implementing the same configuration for the first disk <NUM> and the second disk <NUM> of the adjustable spacer <NUM> provides simplified manufacturing. The adjustable spacer <NUM> further includes a cable tie <NUM>. The cable tie <NUM> is generally a one-piece, self-locking fastener that includes a slot <NUM> for receiving and securing an end <NUM> of the cable tie <NUM> to form a loop.

As best shown in <FIG>, when the adjustable spacer <NUM> is assembled, the cable tie <NUM> is coupled to the first disk <NUM> and the second disk <NUM>. In particular, the end <NUM> of the cable tie <NUM> is inserted through the slot <NUM> to form a loop of a desired size that interfaces with the angled surface <NUM> of the first disk <NUM> and the angled surface <NUM> of the second disk <NUM>. To adjust the thickness D1 of the adjustable spacer <NUM>, the loop of the cable tie <NUM> may be adjusted (e.g., tightened) by pulling the end <NUM> through the slot <NUM>. In particular, to increase the thickness D1 of the adjustable spacer <NUM>, the cable tie <NUM> is tightened, resulting in a smaller loop, which pushes against the angled surfaces <NUM>, <NUM> in a wedge-like manner to move the first disk <NUM> away from the second disk <NUM>. At a widest thickness (e.g., a tightest loop of the cable tie <NUM>), the lips <NUM>, <NUM> catch the cable tie <NUM> and prevent further tightening of the cable tie <NUM>. The thickness D1 of the adjustable spacer <NUM> may additionally be adjusted by altering the width D2 of the cable tie <NUM>. Similar to the screw-type adjustment mechanism <NUM> of adjustable spacer <NUM> and the spring-type adjustment mechanism of the adjustable spacer <NUM>, the wedge-type adjustment mechanism of the adjustable spacer <NUM> provides a continuous transition along the range of thicknesses of the adjustable spacer <NUM> (e.g., as cable tie <NUM> is tightened).

An exploded view of a transformer according to another example not falling within the scope of the claims is illustrated in <FIG> and indicated generally by reference number <NUM>. The transformer <NUM> is similar to transformer <NUM>. However, instead of including adjustable spacer <NUM>, transformer <NUM> includes adjustable spacer <NUM>. Similar to transformer <NUM>, transformer <NUM> includes a plurality of windings <NUM> (e.g., primary and secondary windings) and a core <NUM> which magnetically couples the windings <NUM>. As noted above, the transformer <NUM> also includes adjustable spacer <NUM> having an adjustable thickness D1, which serves to mechanically separate and support the windings <NUM>. As shown in <FIG>, the adjustable spacer <NUM> is positioned between windings <NUM> within a winding area of the transformer <NUM>. In the illustrated embodiment, the adjustable spacer <NUM> is centrally positioned within the transformer <NUM>. By doing so, the adjustable spacer <NUM> is able to position the windings <NUM> away from the air gap of the transformer <NUM>. In this manner, fringing flux associated with the transformer <NUM> may be reduced (e.g., as compared to a transformer including a spacer of a given thickness, etc.).

<FIG> illustrate assembly of transformer <NUM>. In particular, <FIG> illustrates the transformer <NUM> as assembled, prior to adjusting the thickness of the adjustable spacer <NUM>. In particular, the windings <NUM>, core <NUM>, disk <NUM>, cable tie <NUM>, and disk <NUM> are aligned and assembled, however, the end <NUM> of the cable tie <NUM> has not yet been inserted through the slot <NUM>. To ensure the windings <NUM> are positioned away from the air gap of the transformer <NUM> (e.g., to reduce fringing flux, etc.), the cable tie <NUM> is tightened by pulling the end <NUM> through the slot <NUM>. As shown in <FIG>, after the cable tie <NUM> is tightened as desired, the end <NUM> may be removed (e.g., cut) from the cable tie <NUM>.

<FIG> illustrates a cross-sectional view of the transformer <NUM>. As described above, the thickness D1 of the adjustable spacer <NUM> is adjusted by tightening the cable tie <NUM> (e.g., by pulling the end <NUM> through the slot <NUM>). In particular, when the cable tie <NUM> is tightened, the cable tie <NUM> pushes against wedge-shaped disks <NUM>, <NUM>, which pushes the disks <NUM>, <NUM> towards the windings <NUM>, as indicated by arrows <NUM>. In this manner, the windings <NUM> are positioned away from the air gap of the transformer <NUM> and are secured or fixed in such a position as the cable tie <NUM> is self- locking (e.g., inhibited from loosening).

<FIG> illustrate another example of an adjustable spacer <NUM> not falling within the scope of the claims including a wedge-type adjustment mechanism that includes at least one wedge pin <NUM>. Similar to adjustable spacers <NUM>, <NUM>, <NUM> and <NUM>, the adjustable spacer <NUM> is suitable for use in electrical components (e.g., transformers, inductors, etc.) including transformer <NUM>, for example, to separate and/or provide space between windings <NUM> included the transformer <NUM>. Adjustable spacer <NUM> includes a first segment or disk <NUM> and a second segment or disk <NUM>, each of which define a central opening <NUM>. Similar to the wedge-shaped disks <NUM>, <NUM>, the first disk <NUM> includes a lip <NUM> at the opening <NUM> and the second disk <NUM> also includes a lip <NUM> at the opening <NUM>. In the illustrated embodiment, the first disk <NUM> includes an angled surface <NUM>, which slopes down from the lip <NUM> towards an outer edge of the first disk <NUM>. The second disk <NUM> also includes an angled surface <NUM>, which slopes down from the lip <NUM> towards an outer edge of the second disk <NUM>. The adjustable spacer <NUM> further includes at least one wedge pin <NUM>. In particular, the adjustable spacer <NUM> includes two wedge pins <NUM> which include angled surfaces <NUM> that correspond to the angled surface <NUM> of the first disk <NUM> and the angled surface <NUM> of the second disk <NUM>.

Referring to <FIG>, when the adjustable spacer <NUM> is assembled, the wedge pins <NUM> are coupled to the first disk <NUM> and the second disk <NUM>. In particular, the wedge pins <NUM> are inserted, or "wedged," between the first disk <NUM> and the second disk <NUM>. Due to the angled surfaces <NUM> of the wedge pins <NUM>, the thickness D1 of the adjustable spacer <NUM> may be adjusted based on the amount of penetration of the wedge pins <NUM> (e.g., the depth to which the wedge pins <NUM> are inserted between the disks <NUM>, <NUM>). In particular, as the wedge pins <NUM> are inserted between the first disk <NUM> and the second disk <NUM>, the angled surfaces <NUM> of the wedge pins <NUM> interact with the angled surfaces <NUM>, <NUM> to separate the first disk <NUM> away from the second disk <NUM>. Similar to adjustable spacer <NUM>, when the adjustable spacer <NUM> is at a widest thickness (e.g., a greatest penetration by the wedge pins <NUM>), the lips <NUM>, <NUM> catch the cable tie wedge pins <NUM> and prevent further penetration of the wedge pins <NUM>. The thickness D1 of the adjustable spacer <NUM> may additionally be adjusted by altering the width D2 of the wedge pins <NUM>. Similar to the screw-type adjustment mechanism <NUM> of adjustable spacer <NUM> and the spring-type adjustment mechanism of the adjustable spacer <NUM>, the wedge-type adjustment mechanism of the adjustable spacer <NUM> provides a continuous transition along the range of thicknesses of the adjustable spacer <NUM> (e.g., as the wedge pins <NUM> are inserted). Furthermore, while two wedge pins <NUM> are included in adjustment mechanism <NUM>, a greater or lesser number of wedge pins <NUM> may be suitable in other embodiments.

An exploded view of a transformer according to another example not falling within the scope of the claims is illustrated in <FIG> and indicated generally by reference number <NUM> The transformer <NUM> is similar to transformer <NUM>. However, instead of including adjustable spacer <NUM>, transformer <NUM> includes adjustable spacer <NUM>. Similar to transformer <NUM>, transformer <NUM> includes a plurality of windings <NUM> (e.g., primary and secondary windings) and a core <NUM> which magnetically couples the windings <NUM>. As noted above, the transformer <NUM> also includes adjustable spacer <NUM> having an adjustable thickness D1, which serves to mechanically separate and support the windings <NUM>. As shown in <FIG>, the adjustable spacer <NUM> is positioned between windings <NUM> within a winding area of the transformer <NUM>. In the illustrated embodiment, the adjustable spacer <NUM> is centrally positioned within the transformer <NUM>. By doing so, the adjustable spacer <NUM> is able to position the windings <NUM> away from the air gap of the transformer <NUM>. In this manner, fringing flux associated with the transformer <NUM> may be reduced (e.g., as compared to a transformer including a spacer of a given thickness, etc.).

<FIG> illustrate assembly of transformer <NUM> not falling within the scope of the claims. In particular, <FIG> illustrates the transformer <NUM> as assembled, prior to adjusting the thickness of the adjustable spacer <NUM>. In particular, the windings <NUM>, core <NUM>, disk <NUM>, and disk <NUM> are aligned and assembled, however, the wedge pins <NUM> have not yet been inserted between the disks <NUM>, <NUM>. To ensure the windings <NUM> are positioned away from the air gap of the transformer <NUM> (e.g., to reduce fringing flux, etc.), the wedge pins <NUM> are inserted between disk <NUM> and disk <NUM>, as indicated by arrows <NUM>. Prior to insertion, lips <NUM> and <NUM> maintain a small separation between the outer edges of disks <NUM>, <NUM>, such that the tip of the wedge pins <NUM> may be inserted in the small separation. As shown in <FIG>, after the wedge pins <NUM> are inserted to a desired depth (e.g., a desired amount of penetration of the wedge pins <NUM>), assembly of the transformer <NUM> is complete.

<FIG> illustrates a cross-sectional view of the transformer <NUM>. As described above, the thickness D1 of the adjustable spacer <NUM> is adjusted by the amount of penetration of the wedge pins <NUM> between the disks <NUM>, <NUM>. In particular, when as the wedge pins <NUM> are inserted, the angled surfaces <NUM> of the wedge pins <NUM> push against the angled surfaces <NUM>, <NUM> of the disks <NUM>, <NUM>, to adjust the disks <NUM>, <NUM> towards the windings <NUM>, as indicated by arrows <NUM>. In this manner, the windings <NUM> are positioned away from the air gap of the transformer <NUM>.

As described above, transformers <NUM> are suitable for use in a circuit board with any suitable circuit topologies, such as a power supply. In some embodiments, one or more of the transformers <NUM> is used in a switch-mode power supply (SMPS). <FIG> illustrates a SMPS <NUM> according to one example embodiment of the present disclosure that includes the transformer <NUM>. In some examples, the SMPS <NUM> includes the transformer <NUM> and/or the transformer <NUM>. As shown in <FIG>, the SMPS <NUM> includes a power circuit <NUM> and a control circuit <NUM>. The power circuit <NUM> includes an input <NUM> for receiving an input voltage Vin and an output <NUM> for providing an output voltage Vout. As shown in <FIG>, the control circuit <NUM> is coupled to the power circuit <NUM> for regulating the output voltage Vout. Alternatively, the control circuit <NUM> is coupled to the power circuit <NUM> for regulating the input voltage Vin. The control circuit <NUM> is configured to generate a control signal <NUM>. The components included in SMPS <NUM> are exemplary only and the transformer <NUM> is contemplated for use in other circuit topologies, including any other suitable SMPS topologies.

Example embodiments described herein may facilitate use of an adjustable spacer within an electrical component, such as a transformer or an inductor, which provides advantages over use of spacers of a given thickness (e.g., a PCB spacer). For example, the adjustable spacer is adjustable within a range of thicknesses such that a single adjustable spacer may be used with multiple electrical components having the same core size, but different air gaps. The ability to redefine the thickness of the adjustable spacer guarantees the compactness of the materials within the electrical component to comply with various material tolerances. The adjustable spacer also accurately permits a stable leakage inductance. Additionally, by keeping windings within the electrical component away from the air gap, fringing flux may be reduced.

Claim 1:
A switch-mode power supply (<NUM>), comprising:
at least one input (<NUM>);
at least one output (<NUM>); and
a power circuit (<NUM>) coupled between the at least one input (<NUM>) and the at least one output (<NUM>) for converting an input voltage or current to an output voltage or current;
the power circuit (<NUM>) including an electrical component (<NUM>) having windings (<NUM>), an adjustable spacer (<NUM>, <NUM>) positioned between the windings (<NUM>), and a core (<NUM>) magnetically coupling the windings (<NUM>);
the adjustable spacer (<NUM>, <NUM>) including a thickness that is adjustable, characterized by the adjustable spacer comprising:
a first disk (<NUM>, <NUM>);
a second disk (<NUM>, <NUM>); and
means for engaging the first and second disks to adjust a spacing between the first and second disks via rotation of the first disk with respect to the second disk to adjust the thickness.