CN103646756A - High-power-density switching power supply transformer and processing technology thereof - Google Patents
High-power-density switching power supply transformer and processing technology thereof Download PDFInfo
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- CN103646756A CN103646756A CN201310697196.XA CN201310697196A CN103646756A CN 103646756 A CN103646756 A CN 103646756A CN 201310697196 A CN201310697196 A CN 201310697196A CN 103646756 A CN103646756 A CN 103646756A
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Abstract
The invention relates to a high-power-density switching power supply transformer and a processing technology thereof. The outer surfaces of two U-shaped magnetic cores are coated with first insulated rubber tape layers, and primary windings are wound around the outer surfaces of the first insulated rubber tape layers; the outer surfaces of the primary windings are coated with second insulated rubber tape layers, and secondary windings are wound around the outer surfaces of the second insulated rubber tape layers; the outer surfaces of the secondary windings are coated with third insulated rubber tape layers, and feedback windings are wound around the outer surfaces of the third insulated rubber tape layers; the outer surfaces of the feedback windings are coated with fourth insulated rubber tape layers, and the two U-shaped magnetic cores are bonded and fixed into a whole; winding coils are directly wound around the U-shaped magnetic cores, and then the two magnetic cores are bonded together through adhesive to form the transformer. The transformer has the advantages of good electromagnetic coupling, the capability of fast winding through a winding machine and high production efficiency; and at the same time, almost no residual space exists in the transformer, the space utilization rate is high, and the size is small, so that the requirement for high-quality switching power supply products in the market is met.
Description
Technical field
The present invention relates to structure and the processing of transformer, relate in particular to a kind of high power density switching mode power supply transformer and processing technology thereof.
Background technology
On market, high-frequency switch power transformer mainly contains following two kinds of forms now:
(1) winding coil is on plastic cement skeleton, then magnetic core is arranged on skeleton.
The advantage of this transformer is: can use the quick coiling of coil winding machine, production efficiency is high.Shortcoming is: volume relatively (same frequency, equal-wattage) is larger, in magnetic core and enamelled wire, has skeleton to separate, and electromagnetic coupled is not fine.Magnetic core is not complete closure, easily produces electromagnetic leakage.
(2) adopt toroidal core, directly coiling on magnetic core.
The advantage of this transformer is: enamelled wire is directly on magnetic core, and electromagnetic coupled is relatively good, and magnetic core is completely closed, there is no electromagnetic leakage.There is no skeleton, the relatively skeleton transformer of volume is smaller.Shortcoming is: can only by hand enamelled wire one be enclosed and is through on magnet ring, can not use equipment, coiling difficulty be large, and production efficiency is low, and cost is high.Magnet ring center need to reserve winding space in addition.Space availability ratio is not high.
At present, owing to having higher requirement from reducing the aspects such as the volume of Switching Power Supply, the power density that increases Switching Power Supply, raising power supply conversion efficiency to switching mode power supply transformer in market, therefore the switching mode power supply transformer and the corresponding processing technology that need development of new, to meet the need of market.
Summary of the invention
In view of problem and the defect that above-mentioned prior art exists, the present invention, in order to reduce the volume of Switching Power Supply, the power density that increases Switching Power Supply, raising power supply conversion efficiency, develops a kind of high power density switching mode power supply transformer and processing technology thereof especially.
The technical scheme that the present invention takes is: a kind of high power density switching mode power supply transformer, comprise magnetic core, it is characterized in that, described magnetic core is two U-shaped magnetic cores, outer surface at two U-shaped magnetic cores is surrounded by respectively ground floor insulating tape, outer surface at ground floor insulating tape is wound with armature winding, outer surface at armature winding is surrounded by second layer insulating tape, outer surface at second layer insulating tape is wound with secondary winding, outer surface at secondary winding is surrounded by three-layer insulated adhesive tape, outer surface at three-layer insulated adhesive tape is wound with feedback winding, outer surface at feedback winding is surrounded by the 4th layer of insulating tape, again two U-shaped magnetic cores are adhesively fixed and are integrated.
High power density switching mode power supply transformer processing technology of the present invention is as follows: after two U-shaped magnetic cores are wrapped up respectively to one deck insulating tape, be fixed on fixture, fixture is fixed on coil winding machine, by armature winding around U-shaped magnetic core outer surface, from fixture, take off U-shaped magnetic core afterwards, after wrapping up again one deck insulating tape, be fixed on fixture, by secondary winding around its outer surface, from fixture, take off U-shaped magnetic core afterwards, after wrapping up again one deck insulating tape, be fixed on fixture, to feed back winding around its outer surface, from fixture, take off magnetic core afterwards, wrap up again one deck insulating tape, two U-shaped magnetic cores are adhesively fixed and are integrated, after air drying, feedback winding initiating terminal and the end of two U-shaped magnetic core outer surfaces are scalded to tin, finally apply one deck insulating varnish.
Advantage and beneficial effect that the present invention has are: winding coil is directly wound on two U-shaped magnetic cores, then two magnetic cores are sticked with glue to agent bond together, and form a transformer.This transformer has the advantage that electromagnetic coupled is good, has again and can use the quick coiling of coil winding machine, the advantage that production efficiency is high.Transformer inside does not have remaining space substantially simultaneously, and space availability ratio is high, and volume is little.Thereby met the quality requirements of market to switch power supply product.
Accompanying drawing explanation
Fig. 1 is high power density switching mode power supply transformer vertical view;
Fig. 2 is high power density switching mode power supply transformer front view;
Fig. 3 is high power density switching mode power supply transformer end view;
Fig. 4 is the A-A profile of Fig. 2;
Fig. 5 is the partial enlarged drawing of Fig. 4;
Fig. 6 is the fixture schematic diagram for fixed magnetic core.
Embodiment
Below in conjunction with drawings and Examples, the invention will be further described:
With reference to Fig. 1, Fig. 2, Fig. 3, Fig. 4 and Fig. 5, the magnetic core of transformer adopting is two U-shaped FERRITE CORE 1, outer surface two U-shaped FERRITE CORE 1 is surrounded by respectively ground floor insulating tape 2, outer surface at ground floor insulating tape 2 is wound with armature winding 3, outer surface at armature winding 3 is surrounded by second layer insulating tape 4, outer surface at second layer insulating tape 4 is wound with secondary winding 5, outer surface at secondary winding 5 is surrounded by three-layer insulated adhesive tape 6, outer surface at three-layer insulated adhesive tape 6 is wound with feedback winding 7, outer surface at feedback winding 7 is surrounded by the 4th layer of insulating tape 8, again two U-shaped magnetic cores 1 are adhesively fixed and are integrated.
High power density switching mode power supply transformer technological process: wrap insulating tape (circle) à and scald tin à test à packing shipment around secondary winding (enamelled wire) à bag insulating tape (two circles) à around feedback winding (three layer insulation wire) à bag insulating tape (two circles) the bonding magnetic core à of à around armature winding (three layer insulation wire) à bag insulating tape (two circles) à on magnetic core.
The U-shaped magnetic core composition that high power density switching mode power supply transformer adopts is ferrite; Winding composition is enamelled wire or three layer insulation wire; Insulating tape composition is polyimides+gum; Adopt the epoxide-resin glue two U-shaped FERRITE CORE that are adhesively fixed.
In structure due to this product, there is no skeleton, take direct winding mode on magnetic core, therefore the fixture of a fixed magnetic core need to be set on coil winding machine.With reference to Fig. 6, first fixture 9 is fixed on to coil winding machine 10(and adopts automatic coil winding machine, model is TANAC AX-1) on; On fixture 9, be provided with slide block 11 and jackscrew 12; One end of U-shaped magnetic core 1 is put on fixture 9, tightened the jackscrew 12 on fixture, make the slide block 11 on fixture 9 compress U-shaped magnetic core 1, can start coiling.
The contrast under same frequency, equal-wattage of three kinds of transformers sees the following form:
From above contrast, can find out: high power density switching mode power supply transformer has been concentrated the advantage of skeleton transformer and toroidal transformer.
The 250W nature cold switch power transformer (switching frequency 130kHz) of take is example, and the overall dimension that adopts this transformer device structure is (37.5 * 30.5 * 28.5) m
3.
Claims (2)
1. a high power density switching mode power supply transformer, comprise magnetic core, it is characterized in that, described magnetic core is two U-shaped magnetic cores (1), outer surface at two U-shaped magnetic cores (1) is surrounded by respectively ground floor insulating tape (2), outer surface at ground floor insulating tape (2) is wound with armature winding (3), outer surface at armature winding (3) is surrounded by second layer insulating tape (4), outer surface at second layer insulating tape (4) is wound with secondary winding (5), outer surface at secondary winding (5) is surrounded by three-layer insulated adhesive tape (6), outer surface at three-layer insulated adhesive tape (6) is wound with feedback winding (7), outer surface at feedback winding (7) is surrounded by the 4th layer of insulating tape (8), again two U-shaped magnetic cores (1) are adhesively fixed and are integrated.
2. a high power density switching mode power supply transformer processing technology as claimed in claim 1, it is characterized in that, after being wrapped up respectively to one deck insulating tape, two U-shaped magnetic cores are fixed on fixture, fixture is fixed on coil winding machine, by armature winding around two U-shaped magnetic core outer surfaces, from fixture, take off U-shaped magnetic core afterwards, after wrapping up again one deck insulating tape, be fixed on fixture, by secondary winding around its outer surface, from fixture, take off U-shaped magnetic core afterwards, after wrapping up again one deck insulating tape, be fixed on fixture, to feed back winding around its outer surface, from fixture, take off magnetic core afterwards, wrap up again one deck insulating tape, two U-shaped magnetic cores are adhesively fixed and are integrated, after air drying, feedback winding initiating terminal and the end of two U-shaped magnetic core outer surfaces are scalded to tin, finally apply one deck insulating varnish.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310697196.XA CN103646756A (en) | 2013-12-18 | 2013-12-18 | High-power-density switching power supply transformer and processing technology thereof |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201310697196.XA CN103646756A (en) | 2013-12-18 | 2013-12-18 | High-power-density switching power supply transformer and processing technology thereof |
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| CN103646756A true CN103646756A (en) | 2014-03-19 |
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| CN201310697196.XA Pending CN103646756A (en) | 2013-12-18 | 2013-12-18 | High-power-density switching power supply transformer and processing technology thereof |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103997228A (en) * | 2014-06-11 | 2014-08-20 | 航天长峰朝阳电源有限公司 | DC/DC power module with input end and output end with ultrahigh isolation voltage |
| CN105161284A (en) * | 2014-12-19 | 2015-12-16 | 国家电网公司 | High-isolation voltage-resistant power supply manufacture method |
| CN108962562A (en) * | 2018-06-19 | 2018-12-07 | 覃源滔 | A kind of exoskeletal LLC transformer of HC type and its manufacturing method |
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| JP2000114074A (en) * | 1998-10-05 | 2000-04-21 | Sony Corp | Transverse magnetic-field transformer |
| CN101901678A (en) * | 2009-06-01 | 2010-12-01 | 北京动力源科技股份有限公司 | Unframed transformer and processing method thereof |
| CN201689765U (en) * | 2009-11-04 | 2010-12-29 | 北京动力源科技股份有限公司 | Transformer |
| CN102064699A (en) * | 2009-09-17 | 2011-05-18 | Det国际控股有限公司 | Integrated magnetic component |
| CN103366928A (en) * | 2013-08-08 | 2013-10-23 | 韩宝华 | Double-opening magnetic electric equipment iron core component body |
| CN203288400U (en) * | 2013-05-24 | 2013-11-13 | 昂宝电子（上海）有限公司 | Transformer used for flyback switch power supply |
| CN203690055U (en) * | 2013-12-18 | 2014-07-02 | 天津光电惠高电子有限公司 | High-power density switch power supply transformer |
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- 2013-12-18 CN CN201310697196.XA patent/CN103646756A/en active Pending
Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000114074A (en) * | 1998-10-05 | 2000-04-21 | Sony Corp | Transverse magnetic-field transformer |
| CN2366953Y (en) * | 1999-04-29 | 2000-03-01 | 丽的钢铁工业股份有限公司 | Transformer |
| CN101901678A (en) * | 2009-06-01 | 2010-12-01 | 北京动力源科技股份有限公司 | Unframed transformer and processing method thereof |
| CN102064699A (en) * | 2009-09-17 | 2011-05-18 | Det国际控股有限公司 | Integrated magnetic component |
| CN201689765U (en) * | 2009-11-04 | 2010-12-29 | 北京动力源科技股份有限公司 | Transformer |
| CN203288400U (en) * | 2013-05-24 | 2013-11-13 | 昂宝电子（上海）有限公司 | Transformer used for flyback switch power supply |
| CN103366928A (en) * | 2013-08-08 | 2013-10-23 | 韩宝华 | Double-opening magnetic electric equipment iron core component body |
| CN203690055U (en) * | 2013-12-18 | 2014-07-02 | 天津光电惠高电子有限公司 | High-power density switch power supply transformer |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103997228A (en) * | 2014-06-11 | 2014-08-20 | 航天长峰朝阳电源有限公司 | DC/DC power module with input end and output end with ultrahigh isolation voltage |
| CN105161284A (en) * | 2014-12-19 | 2015-12-16 | 国家电网公司 | High-isolation voltage-resistant power supply manufacture method |
| CN105161284B (en) * | 2014-12-19 | 2017-08-04 | 国家电网公司 | The resistance to voltage source manufacture method of high isolation |
| CN108962562A (en) * | 2018-06-19 | 2018-12-07 | 覃源滔 | A kind of exoskeletal LLC transformer of HC type and its manufacturing method |
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Application publication date: 20140319 |