Transformer for LDC of electric vehicle

A transformer for a low DC-DC converter (LDC) of an electric vehicle, the LDC configured to supply power from a high voltage battery of the electric vehicle to electrical components of the electric vehicle, the transformer comprising:

• a primary coil configured to receive a current from the high voltage battery of the electric vehicle;
• a lower secondary coil element attached to a bottom surface of the primary coil to generate an induced current by the current flowing through the primary coil and supply the induced current to the electrical components of the electric vehicle;
• and
• an upper secondary coil element attached to a top surface of the primary coil to generate the induced current by the current flowing through the primary coil and supply the induced current to the electrical components of the electric vehicle,
• wherein the primary coil includes a fine line bunch wire having an insulative coalescing agent and a copper fine line bunch, and further includes:
• an input wire connected to the high voltage battery of the electric vehicle, and having a straight fine line bunch wire;
• a primary side winder extending from the input wire and winding the fine line bunch wire a plurality of times in a plate shape to have a first central hole at a center of the fine line bunch wire wound in the plate shape;
• and
• a straight output wire connected to the high voltage battery of the electric vehicle at an end of the primary side winder,
• wherein the lower secondary coil element includes:
• a lower copper plate coil having a non-flexible copper plate and lower terminals;
• and
• a lower insulation unit having a first synthetic resin material, a lower central hole formed therein, and the lower copper plate coil embedded therein excluding the lower terminals,
• wherein the upper secondary coil element includes:
• an upper copper plate coil having a non-flexible copper plate and upper terminals;
• and
• an upper insulation unit having a second synthetic resin material, an upper central hole formed therein, and the upper copper plate coil embedded therein excluding the upper terminals,
• wherein, as the bottom surface of the primary coil is attached to a top surface of the lower secondary coil element and the top surface of the primary coil is attached to a bottom surface of the upper secondary coil element, the primary coil is attached between the lower secondary coil element and the upper secondary coil element,
• wherein the lower copper plate coil includes:
• a lower first terminal having a first terminal hole formed therein;
• a downward bent portion which is downwardly bent from the lower first terminal;
• a lower winding portion bent horizontally at an end of the downward bent portion, so as to be wound once;
• and
• a lower second terminal extending from an end of the lower winding portion and having a second terminal hole formed therein,
• wherein the upper copper plate coil includes:
• an upper first terminal having a third terminal hole formed therein;
• an upper winding portion extending horizontally from the upper first terminal, so as to be wound once;
• an upward bent portion which is upwardly bent at an end of the upper winding portion;
• and
• an upper second terminal bent horizontally at an end of the upward bent portion and having a fourth terminal hole formed therein,
• wherein, when the primary coil is attached between the lower secondary coil element and the upper secondary coil element, the lower second terminal, the upper second terminal and the downward bent portion are configured such that the second terminal hole and the fourth terminal hole communicate with each other, and that the lower second terminal and the upper second terminal are attached to be in surface contact with each other, so as to be disposed in a vertical direction with respect to each other, and the lower first terminal, the upper first terminal and the upward bent portion are configured such that the lower first terminal and the upper first terminal are placed in a horizontal direction with respect to each other.