WO2025084615A1 - Power supply device comprising transformer - Google Patents

Abstract

The power supply device according to an embodiment comprises: a core unit comprising an upper core and a lower core which is disposed so as to face the upper core in a first direction; a coil unit having a part thereof accommodated between the upper core and the lower core, and including a plurality of terminals protruding in a second direction; an insulating plate having a plurality of through-holes through which the plurality of terminals pass; and a bus bar disposed on the insulating plate.

Description

POWER SUPPLY UNIT INCLUDING TRANSFORMER

The embodiment relates to a power supply device including a transformer.

Power supplies for electronic devices contain various coil components such as transformers and line filters.

Transformers can be included in electronic devices for various purposes. For example, transformers can be used to perform the function of transferring energy from one circuit to another. Transformers can also be used to perform the function of changing the voltage magnitude, either stepping up or stepping down. Also, transformers, which have the characteristic of only inductive coupling between the primary and secondary windings and thus no direct DC path is formed, can be used for the purpose of blocking DC and passing AC or for insulating and separating two circuits. Research is continuously being conducted to improve the performance of such transformers.

An embodiment provides a power supply including a transformer having superior performance.

A power supply device according to an embodiment may include a core portion including an upper core and a lower core arranged to face the upper core in a first direction; a coil portion including a plurality of terminals, some of which are accommodated between the upper core and the lower core and protruding in a second direction; an insulating plate having a plurality of through holes formed to allow each of the plurality of terminals to pass through; and a bus bar arranged on the insulating plate.

For example, the insulating plate may be placed between the core portion and the bus bar.

For example, the insulating plate may be spaced apart from the core portion in the second direction.

For example, the distance spaced in the second direction may be greater than 0 and less than or equal to 3.5 mm.

For example, the bus bar may be in contact with the second surface of the insulating plate.

For example, the bus bar and the insulating plate may be spaced apart at least in part.

For example, the separation distance between the bus bar and the insulating plate may be smaller than the separation distance between the insulating plate and the core portion.

For example, at least a portion of the insulating plate may overlap the core portion in the second direction.

For example, the first thickness of the insulating plate in the second direction may be smaller than the second thickness of the bus bar in the second direction.

For example, the coil portion includes a first coil portion arranged to surround the middle of the core portion; and a second coil portion arranged on at least a portion of the inner side and the outer side of the first coil portion, and the second coil portion includes an inner coil portion arranged on at least a portion of the inner side of the first coil portion; and an outer coil portion arranged on at least a portion of the outer side of the first coil portion, and the inner coil portion includes an inner upper coil portion arranged above the inner side of the first coil portion; and an outer lower coil portion arranged below the inner side of the first coil portion, and the outer coil portion includes an outer upper coil portion arranged above at least a portion of the outer side of the first coil portion; and an outer lower coil portion arranged below at least a portion of the outer side of the first coil portion, and the inner upper coil portion includes a first body arranged above the inner side of the first coil portion; And a first terminal protruding in the first direction intersecting the vertical direction from an upper end of the first body, the inner lower coil portion includes a second body arranged below the inner side of the first coil portion; and a second terminal protruding in the first direction from a lower end of the second body, the outer upper coil portion includes a third body arranged above at least a portion of the outer side of the first coil portion; and a third terminal protruding from the third body in the first direction, the outer lower coil portion includes a fourth body arranged below at least a portion of the outer side of the first coil portion; and a fourth terminal protruding from the fourth body in the first direction, and the plurality of terminals may include the first to fourth terminals.

For example, the first terminal and the second terminal may be opposed to each other in the vertical direction, and the third terminal and the fourth terminal may be opposed to each other in the vertical direction.

For example, the through hole of the insulating plate may include a first through hole through which the first terminal passes; a second through hole through which the second terminal passes; a third through hole through which the third terminal passes; and a fourth through hole through which the fourth terminal passes.

For example, the bus bar may include fifth to eighth through holes corresponding to the first to fourth through holes, respectively, and the first to fourth terminals penetrating the first to fourth through holes may be arranged in the fifth to eighth through holes, respectively.

A power supply device including a transformer according to an embodiment can fix individual busbars as one body, reduce process defects, increase assembly flatness of the busbar, enable the power supply device to be manufactured without a separate additional jig/bobbin/structure, and allow the transformer and busbar to be cooled more quickly.

Figure 1 shows a front perspective view of a transformer according to an embodiment.

Figure 2 shows a rear perspective view of the transformer illustrated in Figure 1.

Figure 3 shows a front perspective view of the transformer illustrated in Figure 1 with the core portion removed.

Figure 4 shows a perspective view of the lower core in the core section illustrated in Figure 1.

Figures 5a and 5b show a perspective view and a plan view, respectively, of the first coil portion illustrated in Figure 1.

Figures 6a and 6b show a perspective view and a plan view, respectively, of the inner coil portion illustrated in Figure 1.

Figures 7a and 7b show a perspective view and a plan view, respectively, of the outer coil portion illustrated in Figure 1.

FIGS. 8a and 8b illustrate a plan view and a local side view, respectively, of a power supply device according to one embodiment.

Figure 9 is a drawing showing the speed at which air flows when the fan illustrated in Figure 8 operates.

Figures 10a and 10b illustrate conceptual exploded cross-sectional views and combined cross-sectional views, respectively, of a power supply device according to another embodiment.

FIGS. 11A to 11D illustrate an exploded perspective view, a combined perspective view, a side view, and a plan view, respectively, of an embodiment of the power supply device illustrated in FIGS. 10A and 10B.

Figure 11e shows a perspective view of the combined power supply device illustrated in Figure 10a with the bus bar (300) removed.

The present invention can have various modifications and various embodiments, and specific embodiments are illustrated and described in the drawings. However, this is not intended to limit the present invention to specific embodiments, but should be understood to include all modifications, equivalents, or substitutes included in the spirit and technical scope of the present invention.

Terms including ordinal numbers such as first, second, etc. may be used to describe various components, but the components are not limited by the terms. The terms are only used to distinguish one component from another. For example, without departing from the scope of the present invention, the second component may be referred to as the first component, and similarly, the first component may also be referred to as the second component. The term and/or includes any combination of a plurality of related described items or any item among a plurality of related described items.

When it is said that a component is "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components in between. On the other hand, when it is said that a component is "directly connected" or "directly connected" to another component, it should be understood that there are no other components in between.

In the description of the embodiments, the description that each layer (film), region, pattern or structure is formed "on" or "under" the substrate, each layer (film), region, pad or pattern includes both being formed directly or via another layer. The reference to "on" or "under" each layer is described with reference to the drawings. In addition, the thickness or size of each layer (film), region, pattern or structure in the drawings may be modified for clarity and convenience of description, and therefore does not entirely reflect the actual size.

The terminology used in this application is only used to describe specific embodiments and is not intended to limit the present invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, it should be understood that the terms "comprises" or "has" and the like are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but do not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Terms defined in commonly used dictionaries, such as those defined in common dictionaries, should be interpreted as having a meaning consistent with the meaning they have in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless expressly defined in this application.

Hereinafter, embodiments will be described in detail with reference to the attached drawings. Regardless of the drawing symbols, identical or corresponding components will be given the same reference numbers and redundant descriptions thereof will be omitted.

In addition, some embodiments are described using a Cartesian coordinate system (x-axis, y-axis, z-axis), and in the Cartesian coordinate system, the x-axis, the y-axis, and the z-axis illustrated in each drawing are orthogonal to each other, but the embodiments are not limited thereto. The x-axis, the y-axis, and the z-axis may intersect each other. Hereinafter, for convenience of description, the x-axis direction is referred to as a first direction, the y-axis direction is referred to as a second direction, and the z-axis direction is referred to as a third direction. However, the first to third directions described in the claims do not necessarily mean the x-axis, the y-axis, and the z-axis, and are expressions for distinguishing different directions.

Hereinafter, a transformer according to an embodiment is described with reference to the attached drawings.

FIG. 1 is a front perspective view of a transformer (100) according to an embodiment, FIG. 2 is a rear perspective view of the transformer (100) illustrated in FIG. 1, FIG. 3 is a front perspective view of the transformer (100) illustrated in FIG. 1 with the core portion (110) removed, FIG. 4 is a perspective view of the lower core (114) in the core portion (110) illustrated in FIG. 1, FIGS. 5a and 5b are a perspective view and a plan view, respectively, of the first coil portion (120) illustrated in FIG. 1, FIGS. 6a and 6b are a perspective view and a plan view, respectively, of the inner coil portion (130) illustrated in FIG. 1, and FIGS. 7a and 7b are a perspective view and a plan view, respectively, of the outer coil portion (140) illustrated in FIG. 1.

Referring to FIGS. 1 to 7b, a transformer (100) according to an embodiment may include a core portion (110) and a coil portion.

The core part (110) has the characteristics of a magnetic circuit and can act as a path for magnetic flux. The core part (110) can include an upper core (112) and a lower core (114). In the case of Fig. 4, only the lower core (114) is illustrated, but the upper core (112) has the same shape as the lower core (114) illustrated in Fig. 4, so the following description of the lower core (114) can also be applied to the upper core (112).

The lower core (114) is positioned opposite to the upper core (112) in a third direction, which is perpendicular to the upper core (112), and can be combined with the upper core (112). The two cores (112, 114) may have shapes that are symmetrical to each other in the vertical direction, or may have asymmetrical shapes. However, in the description below, it is assumed that they have shapes that are symmetrical to each other in the vertical direction for the convenience of explanation.

Each of the upper core (112) and the lower core (114) may include a body portion (BO) in the form of a flat plate and a plurality of leg portions protruding in a third direction from the body portion (BO) and extending along a predetermined direction. The plurality of leg portions may include two outer legs (OL1, OL2) arranged to be spaced apart from each other along a uniaxial direction (e.g., a second direction) on a plane and extending along a uniaxial direction (e.g., a first direction), and one intermediate leg (CL) arranged between the two outer legs (OL1, OL2). In this way, the two first and second outer legs (OL1, OL2) may be spaced apart from each other in the second direction, and the intermediate leg (CL) may be arranged between the first and second outer legs (OL1, OL2).

When the upper core (112) and the lower core (114) are connected vertically, each of the outer and middle legs of the upper core (112) faces the corresponding outer or middle legs of the lower core (114). At this time, a gap of a predetermined distance (for example, 10 μm to 200 μm, but not necessarily limited thereto) may be formed between at least some of the outer or middle leg pairs that face each other. In the case of FIGS. 1 and 2, the gap is exemplified as being ‘0’, but the embodiment is not limited to a specific size of the gap.

Additionally, each of the upper core (112) and the lower core (114) may include a magnetic material, such as, but not necessarily limited to, iron or ferrite.

Meanwhile, the coil portion can be accommodated at least partially between the upper core (112) and the lower core (114).

Hereinafter, the coil section according to the embodiment is specifically described as follows.

According to an embodiment, the coil portion may include a first coil portion (120) and a second coil portion (130, 140).

The first coil portion (120) may be a coil in a wound form, and at least a portion of the coil may be arranged on the inner side of the core portion (110). The first coil portion (120) may be arranged to surround the intermediate leg (CL). At this time, the first coil portion (120) may be formed at the center thereof (120), and may include a through hole (TH) in which the second coil portion (130) and the inner bobbin (IB) are arranged and through which the intermediate leg (CL) passes.

Referring to FIG. 5b, the outer side (120OS) of the first coil portion (120) may include first to fourth outer sides (SS1, SS2, SS3, SS4).

The first outer side (SS1) and the second outer side (SS2) are located on opposite sides in the first direction.

The third outer side (SS3) is positioned between the first outer side (SS1) and the second outer side (SS2), and the fourth outer side (SS4) is positioned on the opposite side of the third outer side (SS3) in a second direction intersecting the first direction.

Meanwhile, according to an embodiment, at least a portion of the second coil portion (130, 140) may be disposed on the inner side of the core portion (110). That is, the second coil portion (130, 140) may be disposed on at least a portion of the inner side (120IS) and the outer side (120OS) of the first coil portion (120).

The second coil portion may include an inner coil portion (130) and an outer coil portion (140).

The inner coil part (130) may be arranged on at least a part of the inner side (120IS) of the first coil part (120), and the outer coil part (140) may be arranged on at least a part of the outer side (120OS) of the first coil part (120).

The inner coil part (130) may include an inner upper coil part (132) and an inner lower coil part (134) that are arranged vertically from each other. The inner upper coil part (132) may be arranged above the inner side (120IS) of the first coil part (120), and the inner lower coil part (134) may be arranged below the inner side (120IS) of the first coil part (120).

The inner upper coil part (132) and the inner lower coil part (134) may have a shape symmetrical in a third direction, which is a vertical direction. The inner upper coil part (132) may include a first upper body (hereinafter referred to as the “first body”) (B1U) and a first upper terminal (hereinafter referred to as the “first terminal”) (PI1U, P12U). The first body (BIU) may be arranged on the upper side of the inner side (120IS) of the first coil part (120). The first terminal (PI1U, PI2U) may protrude in a positive first direction intersecting the vertical direction from an upper end (US1) of the first body (BIU).

The inner upper coil portion (132) may extend in a first direction intersecting the third direction and may include a first inner upper terminal (PI1U) formed at one end of the inner upper coil portion (132) and a second inner upper terminal (PI2U) formed at the other end of the inner upper coil portion (132).

The inner lower coil portion (134) may include a first lower body (hereinafter referred to as the “first body”) (B1L) and a first lower terminal (hereinafter referred to as the “first terminal”) (PI1L, P12L). The first body (BIL) may be arranged on the lower side of the inner side (120IS) of the first coil portion (120). The first terminal (PI1L, PI2L) may protrude in a positive first direction intersecting the vertical direction from an upper end of the first body (BIL).

The inner lower coil portion (134) may extend in the first direction and include a first inner lower terminal (PI1L) formed at one end of the inner lower coil portion (134) and a second inner lower terminal (PI2L) formed at the other end of the inner lower coil portion (134).

As described above, the first terminal (PI1U, PI2U, PI1L, PI2L) may be bent from the inside of the core portion (110) and positioned to protrude from the outside of the core portion (110).

In addition, the inner coil part (130) may include guide protrusions (G1U, G2U) that extend horizontally so as to overlap the upper surface of the first coil part (120) vertically. In this way, the first terminals (PI1U, PI2U, PI1L, PI2L) may be formed at one end of the inner coil part (130), and the guide protrusions (G1U, G2U) may be formed to extend in an area between one end and the other end of the inner coil part (130). That is, each of the inner upper coil part (132) and the inner lower coil part (134) may further include guide protrusions (G1U, G2U).

For example, as illustrated, the guide protrusion (GIU, G2U) may be positioned above the first coil portion (120) by protruding in the negative first direction from the upper end (US2) opposite to the upper end (US1) of the first body (B1U).

In the embodiment, by arranging the guide protrusions (G1U, G2U), the first coil part (120) can be prevented from vertically deviating from the fixed position. That is, the guide protrusions (G1U, G2U) (and/or G1L, G2L) serve to guide the first coil part (120) to be positioned in the fixed position.

The protruding length (L1) of the first terminal (PI1U, PI2U) (or, PI1L, PI2L) may be longer than the protruding length (L24) of the guide protrusion (G1U, G2U) (or, G1L, G2L).

Meanwhile, the outer coil part (140) may include an outer upper coil part (142) and an outer lower coil part (144) arranged vertically from each other.

The outer upper coil portion (142) may be positioned above at least a portion of the outer side (120OS) of the first coil portion (120). The outer lower coil portion (144) may be positioned below at least a portion of the outer side (120OS) of the first coil portion (120).

The outer upper coil portion (142) and the outer lower coil portion (144) may have a shape symmetrical in the third direction, which is the vertical direction.

The outer upper coil portion (142) may include a second upper body (hereinafter referred to as the “second body”) (B2U) and a second upper terminal (hereinafter referred to as the “second terminal”) (PO1U, PO2U). The second body (B2U) may be arranged on at least a portion of the outer side (120OS) of the first coil portion (120). The second terminal (PO1U, PO2U) may protrude in a positive first direction from the second body (B2U).

The outer upper coil portion (142) may extend in the first direction and include a first outer upper terminal (PO1U) formed at one end of the outer upper coil portion (142) and a second outer upper terminal (PO2U) formed at the other end of the outer upper coil portion (142).

Similarly, the outer lower coil portion (144) may include a second lower body (hereinafter referred to as the “second body”) (B2L) and a second lower terminal (hereinafter referred to as the “second terminal”) (PO1L, PO2L). The second body (B2L) may be arranged on at least a portion of the outer side (120OS) of the first coil portion (120). The second terminal (PO1L, PO2L) may protrude in a positive first direction from the second body (B2L).

The outer lower coil portion (144) may extend in the first direction and include a first outer lower terminal (PO1L) formed at one end of the outer lower coil portion (144) and a second outer lower terminal (PO2L) formed at the other end of the outer lower coil portion (144).

Each of one end and the other end of the inner upper coil portion (132), the inner lower coil portion (134), the outer upper coil portion (142), and the outer lower coil portion (144) may be formed to extend in the first direction. That is, the first terminals (PI1U, PI2U, PI1L, PI2L) and the second terminals (PO1U, PO2U, PO1L, PO2L) may be formed to extend equally in the first direction.

Additionally, when viewed in a second direction perpendicular to the first and third directions, the positions of the first outer upper terminal (PO1U), the second outer upper terminal (PO2U), the first outer lower terminal (PO1L), and the second outer lower terminal (PO2L) can be arranged between the first inner upper terminal (PI1U) and the first inner lower terminal (PI1L).

As described above, the coil portion according to the embodiment may include a plurality of terminals protruding in the first direction.

For example, when the transformer (100) operates in a sensor tap structure, the second terminal (PO1U, PO2U) and the first terminal (PI1L, PI2L) may operate as a pair, and the first terminal (PI1U, PI2U) and the second terminal (PO1L, PO2L) may operate as a pair.

According to the embodiment, the inner upper coil part (132) and the outer lower coil part (144) can be electrically connected, and the inner lower coil part (134) and the outer upper coil part (142) can be electrically connected.

Additionally, the outer coil portion (140) may be arranged so that more than 50% of the outer surface area is exposed to the outside of the core portion (110).

Additionally, the second body (B2U, B2L) can cover the second to fourth outer surfaces (SS2, SS3, SS4) of the first coil portion (120) and expose the first outer surface (SS1).

At least one of the first coil portion (120) or the second coil portion (130, 140) described above may be replaced with a Litz wire or a copper plate coil, but the embodiment is not limited thereto.

According to an embodiment, each of the inner coil part (130) and the outer coil part (140) may be a plate-shaped coil.

According to an embodiment, the transformer (100) may further include an inner bobbin (or bobbin) (IB). The inner bobbin (IB) may be placed inside (or inside) the inner coil section (130). The inner bobbin (IB) serves to fix the position of the inner coil section (130).

Below, a power supply device (200) according to one embodiment will be briefly examined with reference to the attached drawing.

Figures 8a and 8b illustrate a plan view and a side view, respectively, of a power supply device (200) according to one embodiment. To aid understanding, Figure 8b illustrates only a transformer (250) and a printed circuit board (210).

A power supply device (200) according to an embodiment may include a printed circuit board (210), a bus bar (230), a rectifier (242), and a transformer (250). In addition, the power supply device (200) may further include a fan (220). In addition, the power supply device (200) may further include an inductor (260). In order to help understanding, a portion that is covered by the bus bar (230) and is not visible in FIG. 8A is indicated with a dotted line.

For example, the printed circuit board (210) and the inductor (260) illustrated in FIG. 8a can perform the same functions as the first printed circuit board (20) and the inductor (200) of the above-described prior art document, respectively, and since the embodiment is not limited to a specific configuration of these (210, 260), a detailed description thereof is omitted.

The transformer (250) is placed on a printed circuit board (210) and is identical to the transformer (100) described with reference to FIGS. 1 to 7b described above, so a duplicate description is omitted.

The bus bar (230) may be placed on top of the transformer (250) and the inductor (260). The bus bar (230) may be electrically connected to the transformer (250) and the inductor (260). For example, the first terminal (PI1U, PI2U, PI1L, PI2L) and the second terminal (PO1U, PO2U, PO1L, PO2L) described above may be electrically connected to the bus bar (230). The terminals may be connected to each other or to external substrates or separate electrical elements through the bus bar (230).

Although not shown, the first and second wires (W1, W2) are connected to the first coil section (120) to supply power to the first coil section (120).

The rectifier (242) may be placed on the side of the transformer (250). The rectifier (242) may rectify an alternating current output through the second coil unit (130, 140) of the transformer (250), and may be, for example, a synchronous rectifier, but the embodiment is not limited to a specific type of the rectifier (242).

Referring to FIG. 8b, a portion covering the second outer surface (SS2) of the second body (B2: B2U, B2L) may be arranged to face a bus bar or printed circuit board (210) for electrical connection.

Hereinafter, transformers of comparative examples and embodiments are described with reference to the attached drawings.

The transformer according to the comparative example may have a configuration similar to the transformer illustrated in Fig. 4 of the prior art document.

The transformer according to the comparative example may have a configuration in which the primary coil and the secondary coil are repeatedly vertically stacked inside the core for the purpose of reducing leakage inductance and increasing efficiency. In this case, the coupling force between the primary coil and the secondary coil increases, so that the efficiency of the component can increase. However, heat may be concentrated in the stacked secondary coil, which may reduce heat dissipation.

In addition, in the case of the comparative example, since the primary coil is placed between the secondary coils, the non-continuous winding structure is complex, which may make the manufacturing process difficult and increase the manufacturing cost.

FIG. 9 is a drawing showing the speed at which air flows when the fan (220) illustrated in FIG. 8a operates.

In general, in a power supply, a bus bar (230) is placed on the top of a transformer (250) and a rectifier (242) is placed on the side of the transformer (250), so that the path through which air flows and the transformer are blocked, making heat dissipation difficult.

As illustrated in FIG. 9, when the fan (220) operates, a large amount of air may flow between the printed circuit board (210) and the transformer (250). Considering this, according to an embodiment, the second body (B2) of the outer coil part (140) disposed on the second outer surface (SS2) so that the outer coil part (140) is exposed to the outside of the core part (110) by more than 50% is disposed to face the printed circuit board (210) as illustrated in FIG. 8b. In this case, the second body (B2) of the outer coil part (140) may be exposed to a path through which a large amount of air flows, so that the surface of the second coil part (140) through which a large current flows is exposed to the air, thereby maximizing the cooling method of the fan (220) and improving the heat dissipation characteristics.

In addition, according to the embodiment, since the outer coil part (140) can play a role of wrapping the first coil part (120) to maintain the overall shape, an outer bobbin is not required, and thus the outer bobbin can be omitted, thereby reducing the unit cost of the transformer.

In addition, according to the embodiment, since the inner and outer coil parts (130, 140) are respectively arranged on the inner side (120IS) and the outer side (120OS) of the first coil part (120), the coupling between the first coil part (120) and the second coil part (130, 140) is increased, so that the leakage inductance of the transformer (100) can be reduced.

In addition, in the case of the embodiment, the inner coil part (130) and the outer coil part (140) are respectively arranged in a symmetrical shape vertically. That is, when the first terminals (PI1U, PI1L, PI2U, PI2L) are arranged and the second terminals (PO1U, PO2U, PO1L, PO2L) are arranged as illustrated, the parts can be driven symmetrically during operation, thereby improving the balance of the parts (so that the magnetic flux is not concentrated in one area).

Hereinafter, a power supply device including a transformer according to another embodiment is described as follows.

FIGS. 10A and 10B illustrate conceptual exploded cross-sectional views and combined cross-sectional views, respectively, of a power supply device according to another embodiment.

A power supply device according to another embodiment may include a transformer (100), an insulating plate (or an insulating fixing member) (400), and a bus-bar (300). In addition, the power supply device may further include a printed circuit board (not shown). In addition, the power supply device may further include a rectifier (not shown). In addition, the power supply device may further include a fan (not shown). In addition, the power supply device may further include an inductor (not shown).

For example, the printed circuit board, rectifier, fan, and inductor of the power supply device illustrated in FIGS. 10a and 10b may be arranged in a similar form to the printed circuit board (210), rectifier (242), fan (220), and inductor (260) illustrated in FIG. 8a, respectively.

The insulating plate (400) includes a plurality of through holes (TH) formed so that each of the plurality of terminals (P1, P2) of the coil section passes through, and may be in a plate shape (or, thin film shape).

The insulating plate (400) may include a first surface (S1) facing the coil portion or core portion (110) and a second surface (S2) opposite the first surface (S1).

An insulating plate (400) can be placed between the core portion (110) and the bus bar (300).

The bus bar (300) can be placed on the insulating plate (400). The bus bar (300) can be placed on the second surface (S2) of the insulating plate (400). In this way, the bus bar (300) can contact the second surface (S2) of the insulating plate (400).

For example, the busbar (300) may be placed above the transformer (100) and the inductor and may be electrically connected to the transformer (100) and the inductor.

The rectifier may be placed on the side of the transformer (100). The rectifier may serve to rectify an alternating current output through a secondary coil of the transformer (100), and may be, for example, a synchronous rectifier, but the embodiment is not limited to a specific type of rectifier.

As illustrated in FIG. 10b, the insulating plate (400) may be spaced apart from the core portion (110) of the transformer (100) in the first direction, and the spaced apart space (SP) may form a path through which a fluid (e.g., air) passes. For example, the width (W) of the path (SP) in the first direction may be greater than 0 and less than or equal to 3.5 mm, but the embodiment is not limited thereto. That is, the insulating plate (400) may be spaced apart from the core portion (110) in the first direction by a distance greater than 0 and less than or equal to 3.5 mm.

Additionally, at least a portion of the insulating plate (400) may overlap the core portion (110) of the transformer (100) in the first direction. That is, the planar area of the insulating plate (400) in the second and third directions may be less than or equal to the planar area of the core portion in the second and third directions.

Additionally, the first thickness (T1) of the insulating plate (400) in the first direction may be smaller than the second thickness (T2) of the bus bar (300) in the first direction, but the embodiment is not limited thereto.

Hereinafter, an example of a power supply device illustrated in FIGS. 10a and 10b will be described with reference to the attached drawings.

FIGS. 11A to 11D illustrate an exploded perspective view, a combined perspective view, a side view, and a plan view, respectively, of an embodiment of the power supply device illustrated in FIGS. 10A and 10B, and FIG. 11E illustrates an assembled perspective view of the power supply device illustrated in FIG. 10A with the busbar (300) removed.

The power supply device illustrated in FIGS. 11A to 11E may include a core portion (110), a coil portion, an insulating plate (400), and a bus bar (300). Here, the core portion (110), the coil portion, the insulating plate (400), and the bus bar (300) are the same as the core portion (110), the coil portion, the insulating plate (400), and the bus bar (300) illustrated in FIGS. 10A and 10B, respectively, and therefore, the same reference numerals are used for the same parts and redundant descriptions are omitted.

When the transformer (100) of the power supply device according to another embodiment is implemented as illustrated in FIGS. 1 to 7B, the power supply device illustrated in FIGS. 11A to 11E will be described as follows. That is, to help understanding, the power supply devices illustrated in FIGS. 10A, 10B, and 11A to 11E include the transformer (100) illustrated in FIGS. 1 to 7B, and redundant descriptions thereof (100) will be omitted by using the same reference numerals. However, as long as a plurality of terminals (e.g., the first terminal and the second terminal) can protrude in the same direction, the power supply device according to another embodiment may include a transformer having a different configuration from the transformer (100) illustrated in FIGS. 1 to 7B.

The transformer (100) can be placed on a printed circuit board.

The plurality of terminals illustrated in FIGS. 10A and 10B may refer to the first and second inner upper terminals (PI1U, PI2U), the first and second inner lower terminals (PI1L, PI2L), the first and second outer upper terminals (PO1U, PO2U), and the first and second outer lower terminals (PO1L, PO2L) described above.

Referring to FIGS. 11A to 11E, the first and second inner upper terminals (PI1U, PI2U) and the first and second inner lower terminals (PI1L, PI2L) may face each other in a third direction, which is a vertical direction, and the first and second outer upper terminals (PO1U, PO2U) and the first and second outer lower terminals (PO1L, PO2L) may also face each other in the third direction.

At this time, the through holes of the insulating plate (400) may include first to fourth through holes (TH1 to TH4).

The first through hole (TH1) includes first-first and first-second through holes (TH11, TH12) through which the first and second inner upper terminals (PI1U, PI2U) pass, respectively, the second through hole (TH2) includes second-first and second-second through holes (TH21, TH22) through which the first and second inner lower terminals (PI1L, PI2L) pass, respectively, the third through hole (TH3) includes third-first and third-second through holes (TH31, TH32) through which the first and second outer upper terminals (PO1U, PO2U) pass, respectively, and the fourth through hole (TH4) includes fourth-first and fourth-second through holes (TH41, TH42) through which the first and second outer lower terminals (PO1L, PO2L) pass, respectively.

Additionally, the bus bar (300) includes fifth to eighth through holes (TH5 to TH8) corresponding to (or communicating with) the first to fourth through holes (TH1 to TH4), respectively.

The first and second inner upper terminals (PI1U, PI2U) penetrating the first through hole (TH1) may be disposed in the fifth through hole (TH5), the first and second inner lower terminals (PI1L, PI2L) penetrating the second through hole (TH2) may be disposed in the sixth through hole (TH6), the first and second outer upper terminals (PO1U, PO2U) penetrating the third through hole (TH3) may be disposed in the seventh through hole (TH7), and the first and second outer lower terminals (PO1L, PO2L) penetrating the fourth through hole (TH4) may be disposed in the eighth through hole (TH8).

Alternatively, according to an embodiment, each of the fifth to eighth through holes (TH5 to TH8) may be replaced with a blind hole.

Each of the first and second inner upper terminals (PI1U, PI2U), the first and second inner lower terminals (PI1L, PI2L), the first and second outer upper terminals (PO1U, PO2U), and the first and second outer lower terminals (PO1L, PI2L) arranged in the fifth to eighth through holes (TH5 to TH8) may be made of, for example, copper (Cu) and fixedly connected to the bus bar (300) using an adhesive or the like.

The bus bar (300) may include a first bus bar and a second bus bar. The first bus bar corresponds to a portion connecting the inner upper coil portion (132) and the outer lower coil portion (144). In addition, the second bus bar corresponds to a portion connecting the inner lower coil portion (134) and the outer upper coil portion (142).

The separation distance between the bus bar (300) and the insulating plate (400) may be smaller than the separation distance between the insulating plate (400) and the core portion (110).

Hereinafter, power supply devices of comparative examples and other embodiments are described with reference to the attached drawings.

In the comparative example, terminals corresponding to the first and second inner upper terminals, the first and second inner lower terminals, the first and second outer upper terminals, and the first and second outer lower terminals of the above-described embodiment are directly connected to the busbar without the intervention of the insulating plate (400). At this time, the first and second inner upper terminals, the first and second inner lower terminals, the first and second outer upper terminals, and the first and second outer lower terminals need to be fixed to the exact position of the busbar, but the busbar arranged on the upper side of the transformer is not supported by a separate support, but is supported only by structures on the lower side and the side of the busbar. Accordingly, since the busbar (300) is composed of separate pieces (302 to 310) that are respectively joined to the first and second inner upper terminals, the first and second inner lower terminals, the first and second outer upper terminals, and the first and second outer lower terminals as illustrated in FIG. 11d, it is difficult to assemble the busbar flatly.

In addition, in the case of the comparative example, since the terminals corresponding to the first and second inner upper terminals, the first and second inner lower terminals, the first and second outer upper terminals, and the first and second outer lower terminals according to the embodiment are only fixed to the bus bar via the adhesive, the positions of the first and second inner upper terminals, the first and second inner lower terminals, the first and second outer upper terminals, and the first and second outer lower terminals coupled to the bus bar are not accurately maintained in place, making it difficult to fix the bus bar.

On the other hand, in the case of the embodiment, after the insulating plate (400) is placed between the busbar (300) and the transformer (100), the first and second inner upper terminals (PI1U, PI2U), the first and second inner lower terminals (PI1L, PI2L), the first and second outer upper terminals (PO1U, PO2U), and the first and second outer lower terminals (PO1L, PO2L) of the transformer (100) are each fixed using the insulating plate (400), and then the first and second inner upper terminals (PI1U, PI2U), the first and second inner lower terminals (PI1L, PI2L), the first and second outer upper terminals (PO1U, PO2U), and the first and second outer lower terminals (PO1L, PO2L) are combined to the busbar (300), so that the individual busbars (302 to 310) are integrally formed. It can be fixed and the process defect rate can be reduced.

In addition, according to the embodiment, the insulating plate (400) can support the bus bar (300), thereby increasing the assembly flatness of the bus bar (300) and enabling the power supply device to be manufactured without a separate additional jig/bobbin/structure.

In addition, according to an embodiment, a space (SP) is provided between the insulating plate (400) and the transformer (100), so that a cooling fluid can flow into and out of this space, thereby cooling the transformer (100) and the bus bar (300) more quickly.

Although the above has been described with reference to embodiments, these are merely examples and do not limit the present invention. Those skilled in the art to which the present invention pertains will recognize that various modifications and applications not exemplified above are possible without departing from the essential characteristics of the present embodiment. For example, each component specifically shown in the embodiments can be modified and implemented. In addition, the differences related to such modifications and applications should be interpreted as being included in the scope of the present invention defined in the appended claims.

The best mode for carrying out the invention has been sufficiently described in the above-mentioned “Best Mode for Carrying Out the Invention.”

A power supply device including a transformer according to an embodiment can be used in electronic devices such as automobiles or home appliances.

Claims (10)

A core portion including an upper core and a lower core positioned opposite to the upper core in a first direction; A coil portion having a plurality of terminals protruding in a second direction, the terminals being accommodated between the upper core and the lower core; An insulating plate having a plurality of through holes formed so that each of the plurality of terminals can pass through; and A power supply unit including a busbar arranged on the above insulating plate. A power supply device in accordance with claim 1, wherein the insulating plate is disposed between the core portion and the bus bar. In the first paragraph, The above insulating plate is a power supply device spaced apart from the core part in the second direction. In the third paragraph, A power supply device in which the distance spaced in the second direction is greater than 0 and less than or equal to 3.5 mm. In the first paragraph, the power supply device in which the bus bar is in contact with the second surface of the insulating plate. In the third paragraph, a power supply device in which the bus bar and the insulating plate are at least partially spaced apart. In Article 6, The distance between the above bus bar and the above insulating plate is A power supply unit having a smaller distance between the insulating plate and the core portion. In the first paragraph, A power supply device wherein at least a portion of the insulating plate overlaps the core portion in the second direction. In the first paragraph, A power supply device wherein the first thickness of the insulating plate in the second direction is smaller than the second thickness of the bus bar in the second direction. In the first paragraph, The above coil part A first coil portion arranged to surround the middle of the core portion; and Including a second coil part each disposed on at least a portion of the inner and outer sides of the first coil part, The above second coil part An inner coil portion arranged on at least a portion of the inner side of the first coil portion; and Including an outer coil portion arranged on at least a portion of the outer side of the first coil portion, The inner coil part above An inner upper coil portion arranged above the inner side of the first coil portion; and Including an outer lower coil portion arranged below the inner side of the first coil portion, The above outer coil part An outer upper coil portion arranged above at least a portion of the outer side of the first coil portion; and Including an outer lower coil portion arranged below at least a portion of the outer side of the first coil portion, The inner upper coil part above A first body arranged above the inner side of the first coil portion; and Including a first terminal protruding in the first direction intersecting the vertical direction from the upper end of the first body, The inner lower coil part above A second body arranged on the lower side of the inner side of the first coil portion; and Including a second terminal protruding in the first direction from the lower end of the second body, The upper outer coil portion above A third body arranged above at least a portion of the outer side of the first coil portion; and Including a third terminal protruding in the first direction from the third body, The outer lower coil part above A fourth body arranged below at least a portion of the outer side of the first coil portion; and Including a fourth terminal protruding in the first direction from the fourth body, A power supply device wherein the plurality of terminals include the first to fourth terminals.

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