CN110400693B

CN110400693B - Manufacturing method of transformer

Info

Publication number: CN110400693B
Application number: CN201910736792.1A
Authority: CN
Inventors: 严宗周
Original assignee: Shenzhen Yuanneng Electric Appliance Co ltd
Current assignee: Shenzhen Yuanneng Electric Appliance Co ltd
Priority date: 2019-08-10
Filing date: 2019-08-10
Publication date: 2024-05-17
Anticipated expiration: 2039-08-10
Also published as: CN110400693A

Abstract

The invention belongs to the field of switching power supplies, and relates to a manufacturing method of a transformer. The method comprises the steps of winding a coil, an insulating tape and a magnetic core on a transformer framework, wherein the coil comprises a primary coil, a feedback coil, a shielding coil and a secondary coil, and the manufacturing method comprises the step of winding the primary coil, the feedback coil, the shielding coil and the secondary coil. By changing the winding process, the feedback coil and the shielding coil adopt a winding method of sectional frequency pressing, so that the EMI and common mode noise are greatly reduced, and the problem that the EMI and common mode noise are solved without increasing a Y capacitor in an electronic product is realized; the feedback coil and the shielding coil are continuously wound, so that the coupling effect between the primary coil and the secondary coil is better, the conversion efficiency is higher, the manufacturing process steps are reduced, the process flow for manufacturing the transformer is optimized, and the production efficiency is further improved.

Description

Manufacturing method of transformer

Technical Field

The invention belongs to the field of switching power supplies, and particularly relates to a method for manufacturing a transformer without a Y capacitor on a switching power supply.

Background

At present, shielding is carried out in a plurality of modes of copper foil or wire wrapping, scattered winding, middle winding or whole layer close winding in the market. Among them, electromagnetic compatibility (EMC, electro Magnetic Compatibility) of electronic and electric products is a very important quality index, which not only relates to the operational reliability and use safety of the products themselves, but also may affect the normal operation of other devices and systems, and relates to the protection problem of electromagnetic environment. Electromagnetic compatibility (EMC) includes the fact that the device itself has a certain electromagnetic immunity (EMS, electro Magnetic Susceptibility) and electromagnetic interference (EMI, electromagnetic Interference) that the electromagnetic interference itself generates cannot have an excessive impact on other electronic products.

Electromagnetic interference (EMI) is divided into two forms, differential mode and common mode, and electromagnetic interference propagation paths are also generally divided into two types: namely a conductive coupling mode and a radiation coupling mode. The common mode problem is simply that the cost is too large from the start of inhibition, the effect is not obvious, and the problem needs to be solved from the source. Because the transformer is a non-ideal element, distributed capacitance exists between windings of the transformer and between turns in the same winding, so that the alternating electromagnetic field can be coupled to a secondary, and the secondary has distributed capacitance to the ground, thereby forming a common-mode interference loop. When the mobile phone is used, common mode noise can be coupled through a mobile phone screen, so that the situation that the mobile phone screen is dead due to screen jumping is caused.

In order to solve the problem of common mode noise, EMI shielding is generally added in the transformer to reduce coupling capacitance between different windings, thereby reducing the generation of EMI interference from the source. Meanwhile, a Y capacitor is also required to be added between the primary and secondary. By adding the Y capacitor, the high-frequency coupling between the primary and secondary can be enhanced, and the frequency turning point is changed, so that a good effect of inhibiting EMI electromagnetic interference is obtained. However, due to the introduction of the Y capacitor, an ac coupling path exists between the primary and the secondary, a certain leakage current is correspondingly generated, and when the Y capacitor fails, a high voltage is output through the Y capacitor.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provide a manufacturing method of a transformer so as to solve the problems of EMI and common mode noise without increasing a Y capacitor in an electronic product.

In order to achieve the above purpose, the present invention adopts the following technical scheme:

A manufacturing method of a transformer comprises the steps of winding a coil and a fixed magnetic core on a transformer framework, wherein the method for winding the coil comprises the following steps:

winding a primary coil, and winding the primary coil on the framework anticlockwise by using a first wire;

winding a first insulating layer, and winding an edge adhesive tape outside the primary coil;

Winding a feedback coil, namely winding the feedback coil outside the first insulating layer in a counter-clockwise segmented manner by using a second wire;

winding a second insulating layer, and winding an insulating tape on the feedback coil layer;

winding a shielding coil, namely winding the shielding coil outside the second insulating layer in a counter-clockwise segmented manner by using a third wire, and then hanging the third wire to a wire hanging column or directly cutting off the third wire;

Winding a third insulating layer, and winding an insulating tape outside the shielding coil;

Winding a secondary coil, and winding the secondary coil outside the third insulating layer by a fourth wire;

Winding a fourth insulating layer, and winding an insulating adhesive tape on the secondary coil;

the fixed magnetic core comprises a magnetic core fixed outside the coil and is connected with a static pin.

Further, the winding part of the framework is divided into at least two sections from top to bottom, and the feedback coil is wound at the position of at least one section of the framework.

Further, the winding part of the framework is divided into at least two sections from top to bottom, and the shielding coil is wound at least one section of the framework.

Further, the feedback coil comprises a three-section wound coil, and the shielding coil comprises a three-section wound coil.

Further, coils in the same layer in the primary coil are arranged in parallel; the coils of the same layer in the feedback coils are arranged in parallel; the coils in the same layer in the shielding coils are arranged in parallel; the coils of the same layer in the secondary coils are arranged in parallel.

Further, the manufacturing method of the transformer further comprises winding a fifth insulating layer outside the magnetic core, namely winding an insulating adhesive tape outside the magnetic core.

Furthermore, the primary coil, the feedback coil and the shielding coil are wound by enameled wires with the diameter of 0.1-0.25 mm.

Further, the secondary coil is wound by triple insulated wires with phi of 0.2-1 mm.

In addition, a manufacturing method of the transformer comprises the steps of winding a coil and fixing a magnetic core on a transformer framework, wherein the method for winding the coil comprises the following steps of:

Winding a feedback coil, namely winding the feedback coil anticlockwise outside the first insulating layer by using a second wire, and then hanging the second wire on a pin, wherein the feedback coil is arranged close to one end of the framework;

Winding a shielding coil, leading out a second wire from the hanging pin, winding the shielding coil on the framework anticlockwise, and then hanging the second wire to the wire hanging column or directly cutting off the second wire, wherein the shielding coil is arranged at one end, far away from the feedback coil, of the framework;

winding a second insulating layer, and winding insulating tapes on the feedback coil layer and the shielding coil layer;

winding a secondary coil, and winding the secondary coil outside the second insulating layer by a third wire;

Winding a third insulating layer, and winding an insulating adhesive tape on the secondary coil;

the fixed magnetic core comprises the steps of fixing the magnetic core outside the coil and connecting the magnetic core with a static pin;

the feedback coil and the shielding coil are arranged on the same layer, and the feedback coil and the shielding coil are continuously wound by a second wire.

Winding a shielding coil, leading out a second wire from the hung pin, winding the shielding coil anticlockwise outside the first insulating layer, and then hanging the second wire to a second wire hanging column or cutting off, wherein the shielding coil is arranged far away from one end of the framework, which is provided with a feedback coil;

The fixed magnetic core comprises, fixing the magnetic core outside the coil;

The invention has the beneficial effects that:

According to the manufacturing process of the sectional frequency pressing, when different frequency bands exceed standards, different turns are wound at the bottom, the middle and the top of the framework to press the frequency, so that EMI and common mode noise are greatly reduced, and the problem that an electronic product is free from increasing Y capacitance to solve the EMI and common mode noise is solved;

In addition, the manufacturing method of continuously winding the feedback coil and the shielding coil ensures that the coupling effect between the primary coil and the secondary coil is better, the conversion efficiency is higher, the manufacturing process steps are reduced, the process flow for manufacturing the transformer is optimized, and the production efficiency is further improved.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention.

In the drawings:

Fig. 1 is a schematic structural diagram of a skeleton according to an embodiment of the present invention;

FIG. 2 is a schematic view of a part of the enlarged structure of the portion A in FIG. 1;

FIG. 3 is a schematic view of another angle of the skeleton according to the first to fifth embodiments of the present invention;

FIG. 4 is a schematic side view of a skeleton according to a sixth embodiment of the invention;

FIG. 5 is another schematic side view of the skeleton of the sixth embodiment of the invention;

FIG. 6 is a schematic top view of a skeleton according to a sixth embodiment of the present invention;

FIG. 7 is a schematic side view of the skeleton of the seventh and eighth embodiments of the present invention;

FIG. 8 is another schematic side view of the skeleton of the seventh and eighth embodiments of the present invention;

FIG. 9 is a schematic top view of the skeleton of the seventh and eighth embodiments of the present invention;

Fig. 10 is a schematic top view of the skeleton of the seventh and eighth embodiments of the present invention.

Detailed Description

Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative and intended to explain the present invention and should not be construed as limiting the invention.

In the description of the present invention, it should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate orientations or positional relationships based on the orientation or positional relationships shown in the drawings, merely to facilitate describing the present invention and simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present invention.

Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the present invention, the meaning of "a plurality" is two or more, unless explicitly defined otherwise.

In the embodiments of the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured" and the like are to be construed broadly and include, for example, either permanently connected, removably connected, or integrally formed; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.

The following describes in detail the examples of the present invention, which are implemented on the premise of the technical solution of the present invention, and detailed embodiments and specific operation procedures are given, but the scope of protection of the present invention is not limited to the following examples.

In an embodiment, the invention provides a transformer, comprising a framework, a coil and a magnetic core; a coil is wound on the framework, and the coil comprises a primary coil, a feedback coil, a shielding coil and a secondary coil; and a magnetic core is sleeved on the framework.

In some embodiments, the primary coil, the feedback coil, the shielding coil and the secondary coil are sequentially wound from inside to outside of the framework, and an insulating layer is arranged between the coil layers.

In other embodiments, the primary coil is disposed proximate an inside of the bobbin; the feedback coil and the shielding coil are arranged on the same layer, and the shielding coil and the feedback coil are formed by continuously winding the same wire; the feedback coil and the shielding coil layer are positioned outside the primary coil; the secondary coil is positioned outside the feedback coil and the shielding coil; in an embodiment, an insulating layer is arranged between the coils of each layer.

In an embodiment, the magnetic core is fixed on the outer side of the coil, and an insulating layer is wound on the outer side of the magnetic core. In some embodiments, the magnetic core is connected to the static leg to enable the transformer to pass the EMI certification. In other embodiments, the magnetic core is not wired.

In the embodiment, one end of the framework, on which the pins are mounted, is defined as the upper end of the framework, and the other end is defined as the lower end of the framework, and the upper end and the lower end of the framework are only used for conveniently explaining the structure of the framework, and are not used for limiting the invention.

Referring to fig. 1 to 10, a first string hanging column 12 is arranged on one side of the upper end of the framework 11; specifically, a wire hanging groove 13 is formed in the first wire hanging post 12, and a wire hanging fulcrum 14 is arranged on one side of the wire hanging groove 13; the wire hanging pivot 14 and the wire hanging groove 13 are arranged on the same side of the first wire hanging column 12. In an embodiment, a second string hanging post 15 is further disposed at the lower end of the framework 11, and the second string hanging post 15 is located at a side of the framework 11 away from the first string hanging post 12.

In the embodiment, the lower end of the skeleton 11 is provided with a plurality of pins for connecting coils; correspondingly, the lower end of the framework is provided with pin bases for installing pins, each pin is installed on one pin base respectively, and grooves are formed between the pin bases.

The transformer disclosed by the invention realizes the sectional frequency-pressing and continuous winding process of the feedback coil and the shielding coil winding by changing the skeleton structure, so that the EMI and common mode noise are greatly reduced by the manufacturing process of the sectional frequency-pressing, and the problem that the EMI and the common mode noise are solved without increasing a Y capacitor in an electronic product is realized; the continuous winding manufacturing method has the advantages that the coupling effect between the primary coil and the secondary coil is better, the conversion efficiency is higher, the manufacturing process steps are reduced, the process flow for manufacturing the transformer is optimized, and the production efficiency is further improved.

The invention provides a manufacturing method of a transformer, and the manufacturing method of the transformer provided by the invention is specifically described by the following embodiment.

Example 1

Referring to fig. 1 to 3, the present invention provides a method for manufacturing a transformer, which includes the steps of:

Winding a primary coil, leading out a single first lead from a third pin 3, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is a enameled wire with the thickness of 0.21mm, three layers of the first wire are wound on the framework for 75 circles, and the coils at the same layer are arranged in parallel without interlacing.

And winding a first insulating layer, and winding 2.3 circles of insulating tape outside the primary coil to form the first insulating layer.

And winding a feedback coil, leading a single second wire out of the fifth pin 5, winding the feedback coil on the framework 11 in a counter-clockwise segmented mode, and then connecting the second wire into the fourth pin 4. In implementation, the second wire is a enameled wire with the thickness of 0.21mm, and one end of the second wire is connected to the fifth pin 5; then, the coil is wound on the framework 11 from the lower end of the framework 11 to the upper end of the framework 11 in three sections anticlockwise, and finally the other end of the second wire is connected to the fourth pin 4. In the embodiment, the upper end of the framework 11 to the lower end of the framework 11 are sequentially divided into an upper section coil, a middle section coil and a lower section coil; the upper section coil is wound for 2 circles, the middle section coil is wound for 3 circles, and the lower section coil is wound for 5 circles; the upper section coil, the middle section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil, the middle section coil and the lower section coil of the feedback coil are arranged on the same layer, and the coils are not staggered. In an embodiment, when the second wire is pulled from the upper end of the framework to the fourth pin 4, an insulating tape is stuck on the feedback coil, so that the wires are not staggered.

Winding a second insulating layer, and winding an insulating tape on the feedback coil layer; specifically, 1.3 turns of insulating tape are wound on the feedback coil.

The shielding coil is wound, a single third wire is led out from the fourth pin 4, the shielding coil is wound on the second insulating layer in a counter-clockwise segmented manner, and then the third wire is hung to the second hanging wire post 15. Specifically, the third wire is an enameled wire with the thickness of 0.21 mm; connecting one end of the third wire to the fourth pin 4; the shielding coil is wound on the third wire outside the second insulating layer from the lower end to the upper end of the framework in a three-section anticlockwise manner, and finally the third wire is hung on the second wire hanging column 15; and when the third wire is pulled to the second wire hanging column 15 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is stuck between the third wire and the second wire hanging column 15, so that the third wire and the shielding coil positioned between the upper end of the framework and the second wire hanging column 15 are insulated, and the wire is prevented from being staggered. In the embodiment, the upper end of the framework 11 to the lower end of the framework 11 are sequentially divided into an upper section coil, a middle section coil and a lower section coil; the upper section coil is wound 3 times, the middle section coil is wound 2 times, and the lower section coil is wound 1 time; the upper section coil, the middle section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil, the middle section coil and the lower section coil of the shielding coil are arranged on the same layer, and the coils are not staggered.

Winding a third insulating layer, and winding an insulating adhesive tape on the shielding coil; specifically, 2 circles of insulating tape are wound outside the shielding coil.

And winding a secondary coil, leading out a single fourth wire from the sixth pin 6, winding the secondary coil on the third insulating layer, and connecting the fourth wire to the seventh pin 6. In an embodiment, the fourth wire is a triple insulated wire of 0.75 mm; specifically, one end of the fourth wire is connected to the sixth pin 6, and then the secondary coil is wound around the fourth wire from the lower end of the framework 11 to the upper side counterclockwise outside the fourth insulating layer; specifically, the fourth wire is wound for 6 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the fourth wire is connected to the seventh pin 7, and when the fourth wire is pulled to the seventh pin 7 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is attached to the secondary coil for insulation, so that the wires are prevented from being staggered.

Winding a fourth insulating layer, and winding an insulating adhesive tape on the secondary coil; specifically, 3 turns of insulating tape are wound outside the secondary coil.

In an embodiment, the coils of each layer are not in collision.

In the embodiment, after the coil is wound, a magnetic core is fixed outside the coil, the magnetic core is fixed on the framework 11, and the magnetic core is connected with the fourth pin 4 through a wire; and then, winding 1 circle of insulating tape outside the magnetic core to insulate the magnetic core from the outside.

In this embodiment, the feedback coil and the shielding coil reduce common mode interference and EMI through segmented voltage frequency, so that the electronic product does not need Y capacitance.

Example two

Winding a primary coil, leading out a single first lead from a third pin 3, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is a enameled wire with the thickness of 0.23mm, the first wire is wound on the framework to be full of three layers for 69 circles, and the coils at the same layer are arranged in parallel and are not staggered.

And winding a first insulating layer, and winding 2 circles of edge adhesive tapes outside the primary coil to form the first insulating layer.

And winding a feedback coil, leading a single second wire out of the fifth pin 5, winding the feedback coil on the framework 11 in a counter-clockwise segmented mode, and then connecting the second wire into the fourth pin 4. In implementation, the second wire is a enameled wire with the thickness of 0.23mm, and one end of the second wire is connected to the fifth pin 5; then, the coil is wound on the framework 11 from the lower end of the framework 11 to the upper end of the framework 11 in three sections anticlockwise, and finally the other end of the second wire is connected to the fourth pin 4. In the embodiment, the upper end of the framework 11 to the lower end of the framework 11 are sequentially divided into an upper section coil, a middle section coil and a lower section coil; the upper section coil is wound 1 turn, the middle section coil is wound 3 turns, and the lower section coil is wound 4 turns; the upper section coil, the middle section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil, the middle section coil and the lower section coil of the feedback coil are arranged on the same layer, and the coils are not staggered. In an embodiment, when the second wire is pulled from the upper end of the framework to the fourth pin 4, an insulating tape is stuck on the feedback coil, so that the wires are not staggered.

And winding the shielding coil, leading a single third wire out of the fourth pin 4, winding the shielding coil on the second insulating layer in a counter-clockwise segmented mode, and then directly cutting the third wire. Specifically, the third wire is an enameled wire with the thickness of 0.23 mm; connecting one end of the third wire to the fourth pin 4; winding the third wire outside the second insulating layer by three sections from the lower end to the upper end of the framework to form a shielding coil in a counterclockwise manner, and finally cutting off the third wire directly; and when the third wire is pulled to the second wire hanging column 15 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is stuck between the third wire and the second wire hanging column 15, so that the third wire and the shielding coil positioned between the upper end of the framework and the second wire hanging column 15 are insulated, and the wire is prevented from being staggered. In the embodiment, the upper end of the framework 11 to the lower end of the framework 11 are sequentially divided into an upper section coil, a middle section coil and a lower section coil; the upper section coil is wound 4 circles, the middle section coil is wound 3 circles, and the lower section coil is wound 2 circles; the upper section coil, the middle section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil, the middle section coil and the lower section coil of the shielding coil are arranged on the same layer, and the coils are not staggered.

Winding a third insulating layer, and winding an insulating adhesive tape on the shielding coil; specifically, 3 circles of insulating tape are wound outside the shielding coil.

And winding a secondary coil, leading out a single fourth wire from the sixth pin 6, winding the secondary coil on the third insulating layer, and connecting the fourth wire to the seventh pin 6. In an embodiment, the fourth wire is a triple insulated wire of 0.2 mm; specifically, one end of the fourth wire is connected to the sixth pin 6, and then the secondary coil is wound around the fourth wire from the lower end of the framework 11 to the upper side counterclockwise outside the fourth insulating layer; specifically, the fourth wire is wound for 8 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the fourth wire is connected to the seventh pin 7, and when the fourth wire is pulled to the seventh pin 7 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is attached to the secondary coil for insulation, so that the wires are prevented from being staggered.

In an embodiment, the coils of each layer are not in collision.

In the embodiment, after the coil is wound, a magnetic core is fixed outside the coil, the magnetic core is fixed on the framework 11, and the magnetic core is connected with the first pin 1 through a wire; and then, winding 1 circle of insulating tape outside the magnetic core to insulate the magnetic core from the outside.

Example III

Winding a primary coil, leading out a single first lead from a third pin 3, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is a enameled wire with the thickness of 0.35mm, and is wound on the framework for 42 circles, and the coils at the same layer are not staggered in parallel.

And winding a feedback coil, leading a single second wire out of the fifth pin 5, winding the feedback coil on the framework 11 in a counter-clockwise segmented mode, and then connecting the second wire into the fourth pin 4. In implementation, the second wire is a enameled wire with the thickness of 0.35mm, and one end of the second wire is connected to the fifth pin 5; then, coils are wound on the framework 11 from the lower end of the framework 11 to the upper end of the framework 11 in two sections anticlockwise, and finally the other end of the second wire is connected to the fourth pin 4. In the embodiment, an upper section coil and a lower section coil are sequentially wound from the upper section of the skeleton 11 to the lower section of the skeleton 11 once; the upper section coil is wound for 3 circles, and the lower section coil is wound for 6 circles; the upper section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil and the lower section coil of the feedback coil are arranged on the same layer, and the coils are not staggered. In an embodiment, when the second wire is pulled from the upper end of the framework to the fourth pin 4, an insulating tape is stuck on the feedback coil, so that the wires are not staggered.

Winding a second insulating layer, and winding an insulating tape on the feedback coil layer; specifically, 2 turns of insulating tape are wound on the feedback coil.

The shielding coil is wound, a single third wire is led out from the fourth pin 4, the shielding coil is wound on the second insulating layer in a counter-clockwise segmented manner, and then the third wire is hung to the second hanging wire post 15. Specifically, the third wire is a enameled wire with the thickness of 0.35 mm; connecting one end of the third wire to the fourth pin 4; continuously winding a shielding coil anticlockwise on the lower section and the upper section of the outer framework of the second insulating layer by the third wire, and finally hanging the third wire on a second hanging wire column 15; and when the third wire is pulled to the second wire hanging column 15 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is stuck between the third wire and the second wire hanging column 15, so that the third wire and the shielding coil positioned between the upper end of the framework and the second wire hanging column 15 are insulated, and the wire is prevented from being staggered. In an embodiment, the upper segment coil is wound 4 turns and the lower segment coil is wound 8 turns; the upper section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil and the lower section coil of the shielding coil are arranged on the same layer, and the coils are not staggered.

And winding a secondary coil, leading out a single fourth wire from the sixth pin 6, winding the secondary coil on the third insulating layer, and connecting the fourth wire to the seventh pin 6. In an embodiment, the fourth wire is a 1mm triple insulated wire; specifically, one end of the fourth wire is connected to the sixth pin 6, and then the secondary coil is wound around the fourth wire from the lower end of the framework 11 to the upper side counterclockwise outside the fourth insulating layer; specifically, the fourth wire is wound for 6 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the fourth wire is connected to the seventh pin 7, and when the fourth wire is pulled to the seventh pin 7 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is attached to the secondary coil for insulation, so that the wires are prevented from being staggered.

In an embodiment, the coils of each layer are not in collision.

In other embodiments, the wound feedback coil may be wound in any one of the upper, middle and lower sections of the bobbin 11 on the basis of the above embodiments. Of course, the feedback coil may be continuously wound in any two of the upper, middle and lower stages of the bobbin 11.

Also, in other embodiments, the wound shield coil may be wound in any one of the upper, middle and lower sections of the bobbin 11 on the basis of the above embodiments. Of course, the shield coil may be continuously wound in any two of the upper, middle and lower sections of the bobbin 11.

Of course, in other embodiments, when winding the feedback coil or the shielding coil, the skeleton 11 may be divided into four segments, five segments, six segments, and other segments, which are actually required to be set according to the performance requirement of the transformer.

In other embodiments, the wire thicknesses of the primary coil, the feedback coil and the shielding coil can be selected from any wire diameter of 0.1mm, 0.15mm, 0.3mm, 0.36mm and the like, and the wire winding number of the wire winding can be adaptively adjusted according to the selection of the wire. The secondary coil is a wire with any wire diameter of 0.2mm to 1.0mm, such as 0.36mm, 0.5mm, 0.90mm and the like, and the winding turns of the secondary coil are adaptively adjusted according to the selection of the wire.

In the above embodiment, the feedback coil and the shielding coil reduce common mode interference and EMI through segmented voltage frequency, so that the electronic product is realized without Y capacitance.

Example IV

Referring to fig. 4 to 6, the present invention provides a method for manufacturing a transformer, which includes the following steps:

Winding a primary coil, leading out a single first lead from a second pin 2, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is a enameled wire with the thickness of 0.14mm, a layer of 135 circles is wound on the framework by the first wire, and the coils at the same layer are arranged in parallel without interlacing; when the first lead is connected from the upper end of the framework to the first pin 1 at the lower end of the framework, an insulating tape is stuck outside the primary coil to directly isolate the first lead from the primary coil, so that the lead is prevented from being staggered.

And winding a feedback coil, leading out a single second wire from the fourth pin 4, winding the feedback coil on the framework 11 in a counter-clockwise segmented mode, and then connecting the second wire into the third pin 3. In implementation, the second wire is a enameled wire with the thickness of 0.14mm, and one end of the second wire is connected to the fourth pin 4; then, the coil is wound on the framework 11 from the lower end of the framework 11 to the upper end of the framework 11 in three sections anticlockwise, and finally the other end of the second wire is connected to the third pin 3. In the embodiment, the upper end of the framework 11 to the lower end of the framework 11 are sequentially divided into an upper section coil, a middle section coil and a lower section coil; the upper section coil is wound 3 times, the middle section coil is wound 6 times, and the lower section coil is wound 11 times; the upper section coil, the middle section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil, the middle section coil and the lower section coil of the feedback coil are arranged on the same layer, and the coils are not staggered. In an embodiment, when the second wire is pulled from the upper end of the framework to the third pin 3, an insulating tape is stuck on the feedback coil, so that the wires are not staggered.

Winding a second insulating layer, and winding an insulating tape on the feedback coil layer; specifically, 1 turn of insulating tape is wound on the feedback coil.

The shielding coil is wound, a single third wire is led out from the third pin 3, the shielding coil is wound on the second insulating layer in a counterclockwise segment, and then the third wire is cut off. Specifically, the third wire is an enameled wire with the thickness of 0.14 mm; connecting one end of a third wire to the third pin 3; and winding the third wire outside the second insulating layer by three sections from the lower end to the upper end of the framework to form a shielding coil in a counterclockwise manner, and finally cutting off the third wire. In the embodiment, the upper end of the framework 11 to the lower end of the framework 11 are sequentially divided into an upper section coil, a middle section coil and a lower section coil; the upper section coil is wound for 6 circles, the middle section coil is wound for 3 circles, and the lower section coil is wound for 1 circle; the upper section coil, the middle section coil and the lower section coil are arranged in a separated mode. In an embodiment, the upper section coil, the middle section coil and the lower section coil of the shielding coil are arranged on the same layer, and the coils are not staggered.

And winding a secondary coil, leading out a single fourth wire from the sixth pin 6, winding the secondary coil on the third insulating layer, and connecting the fourth wire to the fifth pin 5. In an embodiment, the fourth wire is a triple insulated wire with a thickness of 0.4 mm; specifically, one end of the fourth wire is connected to the sixth pin 6, and then the secondary coil is wound around the fourth wire from the lower end of the framework 11 to the upper side counterclockwise outside the fourth insulating layer; specifically, the fourth wire is wound for 10 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the fourth wire is connected to the fifth pin 5, and when the fourth wire is pulled to the fifth pin 5 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is attached to the secondary coil for insulation, so that the wires are prevented from being staggered.

Winding a fourth insulating layer, and winding an insulating adhesive tape on the secondary coil; specifically, 2 turns of insulating tape are wound outside the secondary coil.

In an embodiment, the coils of each layer are not in collision.

In the embodiment, after the coil is wound, a magnetic core is fixed outside the coil, the magnetic core is fixed on the framework 11, and the magnetic core is connected with the third pin 3 through a wire; and then, winding 1 circle of insulating tape outside the magnetic core to insulate the magnetic core from the outside.

On the basis of the fourth embodiment, in other embodiments, the winding feedback coil may be wound in any one of the upper, middle and lower sections of the skeleton 11, and of course, the feedback coil may be continuously wound in any two of the upper, middle and lower sections of the skeleton 11.

Also, in other embodiments, the wound shield coil may be wound in any one of the upper, middle and lower sections of the bobbin 11 on the basis of the fourth embodiment. Of course, the shield coil may be continuously wound in any two of the upper, middle and lower sections of the bobbin 11.

Example five

winding a primary coil, leading out a single first lead from a third pin 3, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is a enameled wire with the thickness of 0.21mm, three layers of the first wire are wound on a framework for 75 circles, and coils on the same layer are arranged in parallel without interlacing; and when the first lead is pulled from the upper end of the framework 11 to the lower end of the framework and connected with the first pin 1, the insulating tape is stuck to separate the first lead from the primary coil, so that the lead is prevented from being staggered.

And winding a feedback coil, wherein a single second wire is led out from a fifth pin 5, the feedback coil is wound on the framework anticlockwise, then the second wire is connected into a fourth pin 4, and the feedback coil is arranged close to one end of the framework. In implementation, the second wire is a enameled wire with the thickness of 0.21mm, and one end of the second wire is connected to the fifth pin 5; then, winding the framework 11 anticlockwise from the lower end of the framework 11 upwards to form 10 loops of coils, and finally hanging a second lead on the fourth pin 4; the feedback coil is wound near the lower end of the bobbin 11. In an embodiment, when the second wire is pulled from the upper end of the framework to the fourth pin 4, an insulating tape is stuck on the feedback coil, so that the wires are not staggered.

And winding a shielding coil, namely leading out a single second wire from the fourth pin 4, winding the shielding coil on the framework anticlockwise, and then hanging the second wire to the second hanging wire post 15, wherein the shielding coil is arranged at one end of the framework far away from the feedback coil. Specifically, in the embodiment, the second wire of the winding feedback coil is directly led out from the fourth pin 4 to the upper end of the skeleton 11, and is directly cut off after being wound counterclockwise for 6 circles, and the shielding coil is wound close to the upper end of the skeleton 11; a gap exists between the shielding coil and the feedback coil; the shielding coil and the feedback coil are wound in the same layer, and the shielding coil and the feedback coil are formed by continuously winding a second wire.

Winding a second insulating layer, and winding an insulating adhesive tape on the feedback coil layer and the shielding coil; specifically, 2 circles of insulating adhesive tapes are wound outside the feedback coil layer and the shielding coil.

And winding a secondary coil, leading a single third wire out of the sixth pin 6, winding the secondary coil on the second insulating layer, and connecting the third wire into the seventh pin 7. In an embodiment, the third wire is a triple insulated wire with the thickness of 0.75 mm; specifically, one end of a third wire is connected to the sixth pin 6, and then the secondary coil is wound on the third wire from the lower end of the framework 11 to the upper side anticlockwise outside the second insulating layer; specifically, the third wire is wound for 6 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the third wire is connected to the seventh pin 7, and when the third wire is pulled to the seventh pin 7 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is adhered to the secondary coil for insulation, so that the wires are prevented from being staggered.

Winding a third insulating layer, and winding an insulating adhesive tape on the secondary coil; specifically, 3 turns of insulating tape are wound outside the secondary coil.

In an embodiment, the coils of each layer are not in collision.

In this embodiment, the feedback coil and the shielding coil are continuously wound, so that the coupling effect between the feedback coil and the shielding coil is better, and the process steps of winding the insulating tape once and conducting wires at the fourth pin once are reduced, so that the process flow for manufacturing the transformer is more optimized, and the production efficiency is further improved.

Example six

Winding a primary coil, leading out a single first lead from a third pin 3, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is selected from enameled wires with the thickness of 0.21mm, the first wire is tightly wound on the framework for 51 circles in total on two layers, and the coils on the same layer are arranged in parallel without interlacing; and when the first lead is pulled from the upper end of the framework 11 to the lower end of the framework and connected with the first pin 1, the insulating tape is stuck to separate the first lead from the primary coil, so that the lead is prevented from being staggered.

And winding a first insulating layer, and winding 1.3 circles of insulating tape outside the primary coil to form the first insulating layer.

Winding a feedback coil, namely leading out a single second wire from a fifth pin 5, directly pulling the second wire to the upper end of a framework 11, hanging the second wire on a first hanging wire column 12, insulating an insulating tape outside the second wire between the fifth pin 5 and the first hanging wire column 12, leading out the second wire from the first hanging wire column 12, winding the feedback coil anticlockwise from the direction close to the upper end of the framework 11 to the lower end of the framework, and hanging the second wire on a fourth pin 4; specifically, the second wire is a three-wire enameled wire with the thickness of 0.21mm, the feedback coil is wound into 7 circles of wires, and finally the second wire is hung on the fourth pin 4; the feedback coil is wound near the upper end of the framework 11; the leads of each loop in the feedback coil are not staggered. In an embodiment, the three wires in the second wire are not wound in a crossing manner.

And winding a shielding coil, leading a single second wire out of the fourth pin 4, clockwise winding the shielding coil at a position close to the lower end of the framework, and then hanging the second wire to the second hanging wire post 15, wherein the shielding coil is arranged at one end of the framework far away from the feedback coil. Specifically, in the embodiment, the second wire of the wound feedback coil is directly led out from the fourth pin 4 to be wound clockwise for 0.5 circle at the lower end of the framework 11 and then is hung on the second wire hanging post 15; the shielding coil is wound close to the lower end of the framework 11, and a gap exists between the shielding coil and the feedback coil; the shielding coil and the feedback coil are wound in the same layer, and the shielding coil and the feedback coil are formed by continuously winding a second wire.

Winding a second insulating layer, and winding an insulating adhesive tape on the feedback coil layer and the shielding coil; specifically, 2.3 circles of insulating tape are wound outside the feedback coil layer and the shielding coil.

And winding a secondary coil, leading a single third wire out of the seventh pin 7, and connecting the third wire into the sixth pin 6 after winding the secondary coil on the second insulating layer. In an embodiment, the third wire is a triple insulated wire with the thickness of 0.55 mm; specifically, one end of a third wire is connected to the seventh pin 7, and then the secondary coil is wound clockwise from the lower end of the framework 11 to the upper side of the second insulating layer; specifically, the third wire is wound for 6 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the third wire is connected to the sixth pin 6, and when the third wire is pulled to the sixth pin 6 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is attached to the secondary coil for insulation, so that the wires are prevented from being staggered.

In an embodiment, the coils of each layer are not in collision.

Example seven

Referring to fig. 7 to 10, the present invention provides a method for manufacturing a transformer, which includes the steps of:

Winding a primary coil, leading out a single first lead from a second pin 2, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is a enameled wire with the thickness of 0.13mm, four layers of 130 circles are wound on the framework, and the coils at the same layer are arranged in parallel and are not staggered.

And winding a feedback coil, wherein a single second wire is led out from a fifth pin 5, the feedback coil is wound on the framework anticlockwise, then the second wire is connected into a fourth pin 4, and the feedback coil is arranged close to one end of the framework. In implementation, the second wire is a enameled wire with the thickness of 0.13mm, and one end of the second wire is connected to the fifth pin 5; then, winding the framework 11 upwards and anticlockwise for 14 circles from the lower end of the framework 11, and finally hanging a second lead on the fourth pin 4; the feedback coil is wound near the lower end of the bobbin 11. In an embodiment, when the second wire is pulled from the upper end of the framework to the fourth pin 4, an insulating tape is stuck on the feedback coil, so that the wires are not staggered.

And winding a shielding coil, leading a single second wire out of the fourth pin 4, winding the shielding coil on the framework anticlockwise, and cutting off the second wire, wherein the shielding coil is arranged at one end of the framework far away from the feedback coil. Specifically, in the embodiment, the second wire of the winding feedback coil is directly led out from the fourth pin 4 to the upper end of the framework 11, and is directly cut off after being wound for 8 times anticlockwise, and the shielding coil is wound close to the upper end of the framework 11; a gap exists between the shielding coil and the feedback coil; the shielding coil and the feedback coil are wound in the same layer, and the shielding coil and the feedback coil are formed by continuously winding a second wire.

And winding a secondary coil, leading a single third wire out of the tenth pin 10, and connecting the third wire into the sixth pin 6 after winding the secondary coil on the second insulating layer. In an embodiment, the third wire is a triple insulated wire with the thickness of 0.4 mm; specifically, one end of a third wire is connected to the tenth pin 10, and then the secondary coil is wound anticlockwise on the second insulating layer at the central position of the framework 11; specifically, the third wire is wound for 8 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the third wire is connected to the sixth pin 6, and when the third wire is pulled to the sixth pin 6 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is attached to the secondary coil for insulation, so that the wires are prevented from being staggered.

Winding a third insulating layer, and winding an insulating adhesive tape on the secondary coil; specifically, 2.3 turns of insulating tape are wound outside the secondary coil.

In an embodiment, the coils of each layer are not in collision.

In the embodiment, after the coil is wound, a magnetic core is fixed outside the coil, and the magnetic core is fixed on the framework 11; and then, winding 1 circle of insulating tape outside the magnetic core to insulate the magnetic core from the outside.

Example eight

winding a primary coil, leading out a single first lead from a second pin 2, winding the skeleton anticlockwise, and then connecting the skeleton with a first pin 1; specifically, the first wire is a enameled wire with the thickness of 0.18mm, three layers of the first wire are wound on the framework for 78 circles, and the coils on the same layer are arranged in parallel and are not staggered.

And winding a feedback coil, wherein a single second wire is led out from a fifth pin 5, the feedback coil is wound on the framework anticlockwise, then the second wire is connected into a fourth pin 4, and the feedback coil is arranged close to one end of the framework. In implementation, the second wire is a enameled wire with the thickness of 0.18mm, and one end of the second wire is connected to the fifth pin 5; then, winding the framework 11 for 10 circles upwards and anticlockwise from the lower end of the framework 11, and finally hanging a second lead on the fourth pin 4; the feedback coil is wound near the lower end of the bobbin 11. In an embodiment, when the second wire is pulled from the upper end of the framework to the fourth pin 4, an insulating tape is stuck on the feedback coil, so that the wires are not staggered.

And winding a shielding coil, leading a single second wire out of the fourth pin 4, winding the shielding coil on the framework anticlockwise, and cutting off the second wire, wherein the shielding coil is arranged at one end of the framework far away from the feedback coil. Specifically, in the embodiment, the second wire of the winding feedback coil is directly led out from the fourth pin 4 to the upper end of the skeleton 11, and is directly cut off after being wound counterclockwise for 6 circles, and the shielding coil is wound close to the upper end of the skeleton 11; a gap exists between the shielding coil and the feedback coil; the shielding coil and the feedback coil are wound in the same layer, and the shielding coil and the feedback coil are formed by continuously winding a second wire.

And winding a secondary coil, leading a single third wire out of the tenth pin 10, and connecting the third wire into the sixth pin 6 after winding the secondary coil on the second insulating layer. In the embodiment, the third wire is a five-wire insulated wire with the diameter of 0.25mm, and the diameter of a single wire is 0.25mm; specifically, one end of a third wire is connected to the tenth pin 10, and then the secondary coil is wound anticlockwise on the second insulating layer at the central position of the framework 11; specifically, the third wire is wound for 5 circles to form a secondary coil, and the wires of all circles are not staggered; finally, the other end of the third wire is connected to the sixth pin 6, and when the third wire is pulled to the sixth pin 6 at the lower end of the framework 11 from the upper end of the framework 11, an insulating tape is attached to the secondary coil for insulation, so that the wires are prevented from being staggered.

Winding a third insulating layer, and winding an insulating adhesive tape on the secondary coil; specifically, 2 turns of insulating tape are wound outside the secondary coil.

In an embodiment, the coils of each layer are not in collision.

In other embodiments, the order of the pins on the skeleton 11 may be adjusted according to the requirement based on the above embodiments, for example, referring to fig. 1, in some embodiments, a first pin on a side of the lower end of the skeleton near the first wire hanging post may be defined as a first pin, and other pins may be defined as second pins to seventh pins counterclockwise. Of course, in some embodiments, a second pin of the lower end of the skeleton near the side of the first string hanging post may be defined as a first pin, and then the other pins are defined as second pins to seventh pins counterclockwise.

In other embodiments, the primary coil, the feedback coil, the shielding coil and the secondary coil may be formed by winding two or more wires in parallel during the winding process; in particular, the feedback coil, the shielding coil and the secondary coil can be formed by adopting two or more wires in parallel winding in the winding process.

In some embodiments, the actual winding number of each layer of coil, the thickness of the wires and the winding layer number can be adjusted according to the actual transformer performance requirement; the number of turns of the insulating tape can also be adjusted according to the performance parameters of the actual transformer.

The above-described embodiments are only one of the preferred embodiments of the present invention, and the ordinary changes and substitutions made by those skilled in the art within the scope of the present invention should be included in the scope of the present invention.

Claims

1. The manufacturing method of the transformer comprises the steps of winding a coil and fixing a magnetic core on a transformer framework, and is characterized in that the method for winding the coil comprises the following steps:

Winding a feedback coil, namely continuously winding the feedback coil in a sectional manner anticlockwise outside the first insulating layer by using a second wire; winding coils in at least two sections of the bottom, middle and top sections of the framework, wherein the number of turns of each coil is different and is arranged separately, the coils are arranged on the same layer, and the coils are not staggered;

winding a shielding coil, continuously winding the shielding coil in a counter-clockwise section outside the second insulating layer by using a third wire, and then hanging the third wire to a wire hanging column or directly cutting off the third wire; winding coils in at least two sections of the bottom, middle and top sections of the framework, wherein the number of turns of each coil is different and is arranged separately, the coils are arranged on the same layer, and the coils are not staggered;

2. The method for manufacturing the transformer according to claim 1, wherein: the coils of the same layer in the primary coil are arranged in parallel; the coils of the same layer in the feedback coils are arranged in parallel; the coils in the same layer in the shielding coils are arranged in parallel; the coils of the same layer in the secondary coils are arranged in parallel.

3. The method for manufacturing the transformer according to claim 1, wherein: the manufacturing method of the transformer further comprises the step of winding a fifth insulating layer outside the magnetic core, namely winding an insulating adhesive tape outside the magnetic core.

4. The method for manufacturing the transformer according to claim 1, wherein: the primary coil, the feedback coil and the shielding coil are wound by enameled wires with the diameter of 0.1-0.4 mm.

5. The method for manufacturing a transformer according to claim 1 or 4, wherein: the secondary coil is wound by triple insulated wires with the diameter of 0.2-1 mm.

6. The manufacturing method of the transformer comprises the steps of winding a coil and fixing a magnetic core on a transformer framework, and is characterized in that the method for winding the coil comprises the following steps:

The feedback coil and the shielding coil are arranged on the same layer, the feedback coil and the shielding coil are continuously wound by a second wire, the number of turns of the feedback coil and the number of turns of the shielding coil are different, and a gap exists between the shielding coil and the feedback coil.