CN102360862B

CN102360862B - High-power annular transformer

Info

Publication number: CN102360862B
Application number: CN201110330066.3A
Authority: CN
Inventors: 徐志瑞
Original assignee: Ningbo Zhongce Et Electronics Co Ltd
Current assignee: Ningbo Zhongce Et Electronics Co Ltd
Priority date: 2011-10-26
Filing date: 2011-10-26
Publication date: 2014-04-09
Anticipated expiration: 2031-10-26
Also published as: CN102360862A

Abstract

The invention relates to a high-power annular transformer, which comprises an annular iron core, a primary coil and a secondary coil both of which are sequentially wound on the annular iron core. The annular iron core is a non-closed annular iron core provided with a gap; an insulated film is lined at the gap; the opposite surface of the gap is a flat surface; the gap is 0.02-0.1 mm in width; copper foils are isolated between the primary coil and the secondary coil; the copper foils are covered on the entire surface of the primary coil of the transformer; the copper foils are uniform in width; and the copper foils are wound and covered at 1/4 of the width of each copper foil on the surface of the primary coil.

Description

High-power annular transformer

Technical field

The present invention relates to electronics and field of electrical equipment, refer to especially a kind of high-power annular transformer.

Background technology

Use is generally to do high-power transformer with EI type transformer at present, that enamelled wire is wound on skeleton, again silicon steel sheet is inserted on skeleton and the EI type transformer forming, EI type transformer structurally, due to the reason of silicon steel sheet scale, overall volume is large, affect the weight of installing space and the product of product, in use, due to the reason of EI type structure, so when design exist iron loss and copper loss greatly, leakage field is large, makes that transformer efficiency is low, temperature rise, noise be large.

Also having a kind of is generally with the iron core toroidal transformer in gap not, to use silicon steel sheet winding shaping, wrap again insulating barrier, after the ring-shaped transformer that forms around enamelled wire, iron core do not crack gap toroidal transformer structurally, the silicon-steel sheet used for iron core winding shaping gap of not cracking, between primary winding and secondary winding without bag screen, in use, due to the iron core gap reason of not cracking, so after transformer energising, inrush current moment increase.Transformer and external connected electronic components and parts are easily damaged, also have transformer in use due to voltage fluctuation, easily make transformer magnetic saturation, and cause that transformer heating is until burn.

Summary of the invention

First object of the present invention is to solve after transformer energising, and inrush current steadily and the in use fluctuation of voltage of transformer, makes transformer magnetic unsaturated, in addition when transformer voltage is exported waveform stabilization without burr, spike;

Another object of the present invention is that to solve transformer bottom surface smooth, makes can not produce between transformer and installation panel resonance, noiseless and facilitates workman to make transformer easy for installation and in handling process and use transformer bottom surface in moving process to damage with Robot actions.

The present invention is achieved by the following technical solutions:

A high-power annular transformer, includes an annular core, is around in successively primary coil and secondary coil on annular core; Described annular core is for arranging apertured non-closed annular core; Described place, gap is lined with insulation film; Described gap apparent surface is plane; Described gap width is 0.02-0.12mm; Between described primary coil and secondary coil, there is screen; Described polymeric barrier layer materials is Copper Foil, the coated whole transformer of described Copper Foil surface; Described Copper Foil width is identical; Described Copper Foil is to superpose and be coated with 1/4th of Copper Foil width when the voluble wrapping of primary coil surface.

As further improvement, described insulation film is mylar.

As further improvement, the width of described insulation film is 0.02-0.12mm; The width of described insulation film adapts with the gap of annular core.

As further improvement, the thickness of described Copper Foil is 0.01-0.1mm.

The invention has the beneficial effects as follows:

1, its efficiency of toroidal transformer is high, temperature rise is low, noise is little.

2, iron core cracks after gap toroidal transformer energising, and inrush current moment is steady.Can not cause damage to transformer and external connected electronic components and parts, voltage fluctuation in transformer uses, can not make transformer produce magnetic saturation.

3, waveform that toroidal transformer is exported after copper-clad paper tinsel between primary and secondary is level and smooth, without burr.

Accompanying drawing explanation

Fig. 1, the cross-sectional view of a kind of high-power annular transformer of the present invention;

Fig. 2, the annular core schematic diagram of a kind of high-power annular transformer of the present invention;

1, annular core 1.1, gap 1.2, insulation film 2, primary coil

3, screen Copper Foil 4, secondary coil 5, epoxy resin layer 6, epoxy resin core

7, handle 8, installing hole 8.1, pit

Embodiment

The embodiment of DETAILED DESCRIPTION The present application below, the example of described embodiment is shown in the drawings, wherein same or similar label represents same or similar element or has the element of identical or similar functions from start to finish, below by the embodiment being described with reference to the drawings, be exemplary, only for explaining the application, and can not be interpreted as the restriction to the application.

The present invention realizes by following technology, and a kind of high-power annular transformer includes an annular core 1, is around in successively primary coil 2 and secondary coil 4 on annular core 1; Described annular core 1 is for being provided with the non-closed annular core in gap 1.1; Described place, gap is lined with insulation film 1.2; Described gap 1.1 apparent surfaces are plane; Described gap width is 0.02-0.12mm; In various embodiments of the present invention, the width in gap is selected respectively 0.02mm, 0.05mm, 0.08mm, 0.1mm, gap that 0.12mm is different, all can realize object of the present invention, and preferred gap width of the present invention is 0.05mm.Between described primary coil 2 and secondary coil 4, there are 3 isolation of screen Copper Foil, the coated whole transformer of described Copper Foil 3 surface; Described Copper Foil width is in the present embodiment identical, and the specification of Copper Foil is the long 18000mm of wide 15mm x; Described Copper Foil is to superpose and be coated with 1/4th of copper sheet width when coated, in other embodiments of the invention also can be according to the different Copper Foils that need to select different size.In the present embodiment, what insulation film was selected is mylar, in other embodiments, also can select other thin-film material.

Embodiments of the invention are realized by following program:

Ring transformer cores is made

Ring transformer cores is made, first with nippon 0.27mm material, be placed on and in material cutting machine, material be slit into 52mm width, also can require to adjust according to transformer different performance the width of material and material, with air pump up-coiler, material is being turned to internal diameter 100mm, the iron core of external diameter 177mm, wherein internal diameter and external diameter can be according to different performance requirement adjustment, again iron core after coiling is well put in annealing furnace and annealed, in the temperature of 450-550 ℃, anneal 5 hours, then temperature being raised to 800-870 ℃ keeps 10 hours, cooling below reducing the temperature to again 300 ℃, etc. cooled iron core epoxy resin coating vacuum paint dipping, after iron core drip-dry, again iron core is put into oven for drying, temperature is 150 ℃ of left and right, dry after 5 hours, iron core is taken out cooling, again iron core is put on wire cutting machine, with the molybdenum filament cutting between diameter 0.02mm-0.12mm, according to different gaps, require to use the molybdenum filament of different-diameter, iron core is cut out to a gap.Select is in the present embodiment that 0.05mm molybdenum filament has cut into 0.05mm gap.Iron core gravitation after cutting must be inward, iron core there will not be and is scattered like this, with 100mm fuse, be lining into bundle of circles iron core gap in iron core again and overhang 1mm, at the impurity of disposing the inside with air gun, again 0.05mm X 52mm X 38.5mm polyester film is put into place, gap, the material of lining in gap can be changed according to different the needing of client, material size is according to the size adjustment of different iron cores, Deng having served as a contrast after polyester film, inner circle fuse is taken away, gap clamps, again on iron core inner circle and cylindrical gap, lower each point two spot welding are lived, make iron core gap free from flaw, dislocation-free.

Between elementary and secondary, wrap screen, first that the Copper Foil of wide x 18000 length of 15mm is stretching, width and length can adjust according to the size of transformer, with 20mm width adhesive tape, touch whole piece Copper Foil again, than Copper Foil width both sides, each reserves 2.5mm to tape width more, another side at Copper Foil pastes 20mm width polyester film again, than Copper Foil width both sides, each reserves 2.5mm to polyester film width more, make polyester film allow Copper Foil insulate together with adhesive tape sticking, adopt the above Copper Foil of processing to be coated primary coil, coated with 1/4 stacked system, stack width can be according to the size adjustment of transformer, encase whole transformer wire bag, on Copper Foil, welding a lead-in wire draws again, the position of wire bonds can be adjusted according to the different needs of client.

Epoxy resin is filled with in transformer endoporus and bottom surface, first make the mould of an aluminum material, mold materials can need change according to difference, mould size needs to make according to transformer size and installation, again mould is soaked into release agent, after drying, again mould is lain on operating desk, at mould upper epoxy resin layer 5, thickness is 2mm, thickness can be according to the weight adjustment of transformer, after epoxy resin layer 5 solidifies, epoxy resin upper epoxy resin after solidifying again, thickness 8mm, thickness can need to adjust according to transformer difference, and horse back is put into toroidal transformer, add again micro-epoxy resin, make epoxy resin the same with mold height, about 2-3 hour at the temperature between 30 ℃ and 40 ℃ again, can adjust the time according to different temperature, when surface gel, in transformer inner circle, put into handle 7 again, handle 7 exceeds transformer surface 50mm, can adjust length according to different action needs, after epoxy resin cure, again at transformer inner circle casting epoxy resin, till watering the scale of mould, it is epoxy core 6 herein, inner circle epoxy resin core 6 highly can be according to different installation requirement adjustment, epoxy resin core 6 curing and demolding of inner circle such as again.When casting, reserve installing hole 8 and pit 8.1.

The above is only the preferred embodiment of the present invention; it should be pointed out that for the person of ordinary skill of the art, do not departing under the prerequisite of the application's principle; can also make some improvements and modifications, improvements and modifications also should be considered as the application's protection range like this.

Claims

1. a high-power annular transformer, includes an annular core, is around in successively primary coil and secondary coil on annular core, it is characterized in that: described annular core is for arranging apertured non-closed annular core; Described place, gap is lined with insulation film; Described gap apparent surface is plane; Described gap width is 0.02-0.1mm; Between described primary coil and secondary coil, there is screen; The material of described screen is Copper Foil, the coated whole transformer of described Copper Foil surface; Described Copper Foil width is identical; Described Copper Foil is to superpose and be coated with 1/4th of Copper Foil width when the voluble wrapping of primary coil surface;

The production process of described iron core is, iron core after coiling is well put in annealing furnace and annealed, in the temperature of 450-550 ℃, anneal 5 hours, then temperature is raised to 800-870 ℃ and keeps 10 hours, more cooling below reducing the temperature to 300 ℃, wait cooled iron core epoxy resin coating vacuum paint dipping, after iron core drip-dry, again iron core is put into oven for drying, temperature, 150 ℃ of left and right, is dried 5 hours;

The production process in described gap is that the cutting of use molybdenum filament, cuts out a gap iron core;

The put procedure of described insulation film is, with fuse, be lining into bundle of circles iron core gap in iron core and overhang 1mm, with air gun, dispose the impurity of the inside, again polyester film is put into place, gap, Deng having served as a contrast after polyester film, inner circle fuse to be taken away, gap clamps, in upper and lower each point two spot welding of iron core inner circle and cylindrical gap, live again, make iron core gap free from flaw, dislocation-free;

The production process of described screen is, between elementary and secondary, wrap screen, first that Copper Foil is stretching, with adhesive tape, touch whole piece Copper Foil again, than Copper Foil width both sides, each reserves 2.5mm to tape width more, another side at Copper Foil pastes polyester film again, than Copper Foil width both sides, each reserves 2.5mm to polyester film width more, make polyester film allow Copper Foil insulate together with adhesive tape sticking, adopt the above Copper Foil of processing to be coated primary coil, coated with 1/4 stacked system, encase whole transformer wire bag, then on Copper Foil, weld a lead-in wire and draw;

Epoxy resin is filled with in transformer inner circle and bottom surface, at mould upper epoxy resin layer, after epoxy resin layer solidifies, epoxy resin upper epoxy resin after solidifying again, and horse back is put into toroidal transformer, add again micro-epoxy resin, make epoxy resin the same with mold height, about 2-3 hour at the temperature between 30 ℃ and 40 ℃ again, when surface gel, in transformer inner circle, put into handle again, handle exceeds transformer surface, after epoxy resin cure, again at transformer inner circle casting epoxy resin, till watering the scale of mould, it is epoxy core herein, the epoxy resin core curing and demolding of isallobaric device inner circle again.

2. high-power annular transformer according to claim 1, is characterized in that: the width of described insulation film is 0.02-0.1mm; The width of described insulation film adapts with the gap of annular core.

3. high-power annular transformer according to claim 1, is characterized in that: the thickness of described Copper Foil is 0.01-0.1mm.