CN111430133A - Half-turn structure of transformer coil and winding method thereof - Google Patents

Abstract

The invention discloses a half-turn structure of a transformer coil and a winding method thereof, belonging to the technical field of high-frequency switching power supply transformers, and comprising a half-turn coil, wherein the half-turn coil passes through one window on a magnetic core/iron core of a transformer at a single time, the coil characteristic of 0.5 turn is realized through the half-turn coil, and the magnetic core/iron core of the transformer is provided with two windows. The invention changes the traditional mode that the equivalent transformation effect is achieved by simultaneously enlarging the coils at the two sides by two times, improves the utilization rate of the magnetic core window of the transformer, greatly reduces the loss of wires and reduces the manufacturing cost; and the multilayer PCB copper foil or plane copper plate structure replaces the traditional copper wire, so that the metal consumption is reduced, the smaller internal resistance characteristic is realized, the same window area has higher overcurrent capacity by adopting the laminated structure, the surface area of the conductive wire is large, the heat dissipation effect is better than that of the traditional form, the leakage inductance is smaller than that of the traditional winding form, the higher power density can be realized, and the switching frequency is higher.

Description

Half-turn structure of transformer coil and winding method thereof

Technical Field

The invention relates to the technical field of high-frequency switching power supply transformers, in particular to a half-turn structure of a transformer coil and a winding method thereof.

Background

A transformer is a commonly used electrical device. The device is a device for changing alternating voltage by using the principle of electromagnetic induction, and main components are a primary coil, a secondary coil and an iron core (magnetic core). The main functions are as follows: voltage transformation, current transformation, impedance transformation, isolation, voltage stabilization (magnetic saturation transformer), and the like. According to the application, the method can be divided into: power transformers and special transformers (furnace transformers, rectification transformers, power frequency test transformers, voltage regulators, mining transformers, audio transformers, intermediate frequency transformers, high frequency transformers, impact transformers, instrument transformers, electronic transformers, reactors, mutual inductors, etc.).

In order to meet the requirements of a use scene, when a transformer is manufactured, a primary coil and a secondary coil are often designed according to a transformation ratio, and in the existing transformer, in order to achieve an equivalent transformation effect of half turns, even-numbered times of the primary coil and the secondary coil are often amplified synchronously. In popular terms, when a transformer with a transformation ratio of 2:0.5 needs to be manufactured, the existing winding technology is to enlarge two sides of 2:0.5 by two times simultaneously, so that the turn ratio of a primary coil to a secondary coil is 4: 1, the equivalent transformation effect of half turn is realized while the transformation ratio is kept unchanged.

The structure and the winding mode of the coil have certain disadvantages, the utilization rate of a magnetic core window of the transformer is reduced, the loss of the wire is increased, the heat loss of the wire is increased in the working process, and the working state of the power tube in certain specific topologies is influenced due to large leakage inductance caused by a plurality of layers of the coil. Therefore, a half-turn structure of a transformer coil and a winding method thereof are provided.

Disclosure of Invention

The technical problem to be solved by the invention is as follows: how to solve the magnetic core window utilization rate that current coil structure exists little, the high problem of wire rod loss, provide a transformer coil half-turn structure.

The invention solves the technical problem by the following technical scheme, and the transformer comprises a half-turn coil, wherein the half-turn coil passes through one window on a magnetic core/iron core of the transformer once, the coil characteristic of 0.5 turn is realized by the half-turn coil, and the magnetic core/iron core of the transformer is provided with two windows.

Further, the transformer is a planar transformer or a planar transformer.

Further, the shape of the core/core is PQ-type or E-type.

Furthermore, the half-turn structure further comprises at least one whole-turn coil, the whole-turn coil passes through two windows on the transformer magnetic core simultaneously at a time, the coil characteristic of 1 turn is realized through the whole-turn coil, and the half-turn coil is connected with the whole-turn coil in series.

Furthermore, the half-turn coil and the whole-turn coil are both made of flat conductive materials.

Furthermore, the conductive material is any one of a plane copper plate, a flat enameled wire, a copper sheet and a PCB copper foil.

Furthermore, the half-turn coil and the whole-turn coil are arranged in a wiring layer of a single-layer PCB or each wiring layer of a multi-layer PCB in a PCB copper foil wire mode, and PCB copper foils in each wiring layer of the multi-layer PCB are connected in parallel to form the half-turn coil and the whole-turn coil. The multi-layer PCB is adopted, so that the overcurrent capacity of the same window area is higher, the surface area of the conducting wire is large, the heat dissipation effect is better than that of the traditional form, and the leakage inductance is smaller than that of the traditional winding form.

Furthermore, the half-turn coil and the whole-turn coil are formed by connecting a plurality of layers of plane copper plates in parallel. The multilayer plane copper plate structure is used for replacing the traditional copper wire, so that the metal consumption is reduced, the smaller internal resistance characteristic is realized, the same window area has higher overcurrent capacity, the surface area of the conductive wire is large, the heat dissipation effect is better than that of the traditional form, and the leakage inductance is smaller than that of the traditional winding form.

Furthermore, the number of the whole-turn coil and the half-turn coil in the primary coil and the secondary coil of the transformer is set according to the transformation ratio of the transformer. The traditional mode that the equal transformation effect is achieved by simultaneously enlarging two times of the coils on the two sides is changed, the utilization rate of the magnetic core window of the transformer is improved, the loss of wires is greatly reduced, and the manufacturing cost is reduced.

The invention also provides a winding method of the half-turn structure of the transformer coil, which can be used for winding the half-turn structure of the transformer coil and comprises the following steps:

s1: winding a half-turn coil

One coil passes through one window of the transformer magnetic core with two windows at a time to form a half-turn coil;

s2: winding the whole turn coil

Simultaneously passing the other coil through two windows on the magnetic core of the transformer at a time to form a whole-turn coil;

s3: connected into a half-turn structure

And sequentially connecting a half-turn coil and a plurality of whole-turn coils in series according to the transformer transformation ratio to form a half-turn structure (the half-turn structure is simply processed to form a primary coil or a secondary coil of the transformer).

Compared with the prior art, the invention has the following advantages: the half-turn structure of the transformer coil and the winding method thereof change the traditional mode that the equivalent transformation effect is achieved by simultaneously enlarging the coils at two sides by two times, improve the utilization rate of the magnetic core window of the transformer, greatly reduce the loss of wires and reduce the manufacturing cost; and replace traditional copper wire with multilayer PCB copper foil or plane copper plate structure, reduced the metal consumption and realized littleer internal resistance characteristic, adopt the laminated structure to make the same window area overcurrent capacity higher, the conductor wire surface area is big, and the radiating effect is better than traditional form, and the leakage inductance is littleer than traditional coiling form, can realize higher power density, is suitable for higher switching frequency, and it is simpler to coil, and application scope is bigger, is worth using widely.

Drawings

Fig. 1 is a schematic structural diagram of a primary coil in a second embodiment of the present invention;

FIG. 2 is a schematic structural diagram of a secondary coil according to a second embodiment of the present invention;

fig. 3 is a schematic flow chart of a winding method of a half-turn structure of a transformer coil according to a second embodiment of the present invention.

Detailed Description

The following examples are given for the detailed implementation and specific operation of the present invention, but the scope of the present invention is not limited to the following examples.

Example one

The embodiment provides a technical scheme: a half-turn structure of a transformer coil comprises a half-turn coil, wherein the half-turn coil passes through one window on a transformer magnetic core/iron core at a time, the coil characteristic of 0.5 turn is realized through the half-turn coil, and the transformer magnetic core/iron core is provided with two windows.

The transformer is a flat-plate transformer or a planar transformer.

The shape of the magnetic core/iron core is PQ type or E type.

The half-turn structure further comprises at least one whole-turn coil, the whole-turn coil simultaneously penetrates through two windows on the magnetic core of the transformer at a single time, the coil characteristic of 1 turn is realized through the whole-turn coil, and the half-turn coil is connected with the whole-turn coil in series. In other words, the half-turn structure is a structure including half-turn coils, and the number of the whole-turn coils may be 0 or other numbers as long as the half-turn coils are included.

And the half-turn coil and the whole-turn coil are both made of flat conductive materials.

The conductive material is any one of a plane copper plate, a flat enameled wire, a copper sheet and a PCB copper foil, and can also be a conductive structure formed by a mould or other processing means.

The half-turn coil and the whole-turn coil are arranged in a wiring layer of a single-layer PCB or each wiring layer of a multi-layer PCB in a PCB copper foil wire mode, and PCB copper foils in each wiring layer of the multi-layer PCB are connected in parallel to form the half-turn coil and the whole-turn coil. The multi-layer PCB is adopted, so that the overcurrent capacity of the same window area is higher, the surface area of the conducting wire is large, the heat dissipation effect is better than that of the traditional form, and the leakage inductance is smaller than that of the traditional winding form.

The half-turn coil and the whole-turn coil can be formed by connecting a plurality of layers of plane copper plates in parallel. The multilayer plane copper plate structure is used for replacing the traditional copper wire, so that the metal consumption is reduced, the smaller internal resistance characteristic is realized, the same window area has higher overcurrent capacity, the surface area of the conductive wire is large, the heat dissipation effect is better than that of the traditional form, and the leakage inductance is smaller than that of the traditional winding form.

The number of the whole-turn coil and the half-turn coil in the primary coil and the secondary coil of the transformer are set according to the transformation ratio of the transformer. The traditional mode that the equal transformation effect is achieved by simultaneously enlarging two times of the coils on the two sides is changed, the utilization rate of the magnetic core window of the transformer is improved, the loss of wires is greatly reduced, and the manufacturing cost is reduced.

The embodiment also provides a winding method of the half-turn structure of the transformer coil, and the method can be used for winding the half-turn structure of the transformer coil, and comprises the following steps:

s1: winding a half-turn coil

One coil passes through one window of the transformer magnetic core with two windows at a time to form a half-turn coil;

s2: winding the whole turn coil

Simultaneously passing the other coil through two windows on the magnetic core of the transformer at a time to form a whole-turn coil;

s3: connected into a half-turn structure

And sequentially connecting a half-turn coil and a plurality of whole-turn coils in series according to the transformer transformation ratio to form a half-turn structure (the half-turn structure is simply processed to form a primary coil or a secondary coil of the transformer).

Example two

As shown in fig. 1 to 2, the transformer of the present embodiment includes a PQ-type core 1, a first window 12 and a second window 11 symmetrically disposed on the PQ-type core 1, and a primary coil and a secondary coil.

The primary coil comprises 1 first half-turn coil 22, and a first full-turn coil 21 (represented by a thicker line in fig. 1), the first full-turn coil 21 passes through the first window 12 and the second window 11 inside the PQ-type magnetic core 1, and the tail end of the first full-turn coil 21 is connected with the head end of the first half-turn coil 22 to form a first connection terminal 23, the tail end of the first half-turn coil 22 passes through the second window 11 but does not pass through the inside of the first window 12, and is wound from the outside of the PQ-type magnetic core 1, and the tail end of the first half-turn coil 22 and the head end of the first full-turn coil 21 are input terminals 24 of the primary coil.

The secondary coil comprises a second half-turn coil 32 and two second full-turn coils 31 (represented by thicker lines in fig. 1), wherein both the two second full-turn coils 31 pass through the first window 12 and the second window 11 inside the PQ-type magnetic core 1, the tail end of the first second full-turn coil 31 is connected with the head end of the second full-turn coil 31, the tail end of the second full-turn coil 31 is connected with the head end of the second half-turn coil 32, the tail end of the second half-turn coil 32 passes through the second window 11 but does not pass through the inside of the first window 12 but winds from the outside of the PQ-type magnetic core 1, and the tail end of the second half-turn coil 32 and the head end of the first second full-turn coil 31 are output ends 34 of the secondary coil.

The requirement of the transformer on the transformation ratio is 1.5:2.5, so that the primary coil and the secondary coil of the transformer are designed by utilizing the half-turn structure to meet the requirement of the transformation ratio, namely the number of the whole-turn coil and the half-turn coil are set according to the transformation ratio of the transformer. The traditional mode that the equal transformation effect is achieved by simultaneously enlarging two times of the coils on the two sides is changed, the utilization rate of the magnetic core window of the transformer is improved, the loss of wires is greatly reduced, and the manufacturing cost is reduced.

When the transformation ratio is required to be 0.5: N +0.5, wherein N is a positive integer, the number of the whole turns of coils in the secondary coil is increased to N, so that an N + 0.5-form half-turn structure is formed, and the transformer is more convenient to design.

As shown in fig. 3, this embodiment further provides a winding method of a half-turn structure of a transformer coil, and the method can be used to wind the half-turn structure of the transformer coil, and includes the following steps:

s1: winding a half-turn coil

Passing a coil through one of the windows on the transformer core at a time to form a half-turn coil;

s2: winding the whole turn coil

Simultaneously passing the other coil through two windows on the magnetic core of the transformer at a time to form a whole-turn coil;

s3: connected into a half-turn structure

And sequentially connecting a half-turn coil and a plurality of whole-turn coils in series according to the transformer transformation ratio to form a half-turn structure (the half-turn structure is simply processed to form a primary coil or a secondary coil of the transformer).

In summary, the half-turn structure of the transformer coil and the winding method thereof in the two embodiments change the traditional way of achieving the equivalent transformation effect by simultaneously enlarging the two side coils by two times, improve the utilization rate of the transformer core window, greatly reduce the loss of wires, and reduce the manufacturing cost; and replace traditional copper wire with multilayer PCB copper foil or plane copper plate structure, reduced the metal consumption and realized littleer internal resistance characteristic, adopt the laminated structure to make the same window area overcurrent capacity higher, the conductor wire surface area is big, and the radiating effect is better than traditional form, and the leakage inductance is littleer than traditional coiling form, can realize higher power density, is suitable for higher switching frequency, and it is simpler to coil, and application scope is bigger, is worth using widely.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.

In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.

Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.

Claims (10)

1. A half-turn structure of a transformer coil is characterized in that: the transformer comprises a half-turn coil which passes through one window on a transformer magnetic core/iron core at a time, and the coil characteristic of 0.5 turn is realized through the half-turn coil, and the transformer magnetic core/iron core is provided with two windows.

2. The half-turn structure of the transformer coil according to claim 1, wherein: the transformer is a flat-plate transformer or a planar transformer.

3. The half-turn structure of the transformer coil according to claim 1, wherein: the magnetic core/iron core is PQ type or E type.

4. The half-turn structure of the transformer coil according to claim 1, wherein: the half-turn structure further comprises at least one whole-turn coil, the whole-turn coil simultaneously penetrates through two windows on the magnetic core of the transformer at a single time, the coil characteristic of 1 turn is realized through the whole-turn coil, and the half-turn coil is connected with the whole-turn coil in series.

5. The half-turn structure of the transformer coil according to claim 4, wherein: and the half-turn coil and the whole-turn coil are both made of flat conductive materials.

6. The half-turn structure of the transformer coil according to claim 5, wherein: the conductive material is any one of a plane copper plate, a flat enameled wire, a copper sheet and a PCB copper foil.

7. The half-turn structure of the transformer coil according to claim 6, wherein: the half-turn coil and the whole-turn coil are arranged in a wiring layer of a single-layer PCB or each wiring layer of a multi-layer PCB in a PCB copper foil wire mode, and PCB copper foils in each wiring layer of the multi-layer PCB are connected in parallel to form the half-turn coil and the whole-turn coil.

8. The half-turn structure of the transformer coil according to claim 6, wherein: the half-turn coil and the whole-turn coil are both multilayer plane copper plates which are connected in parallel.

9. The half-turn structure of the transformer coil according to claim 4, wherein: the number of the whole-turn coil and the half-turn coil in the primary coil and the secondary coil of the transformer are set according to the transformation ratio of the transformer.

10. A winding method of a half-turn structure of a transformer coil, which is used for winding the half-turn structure of the transformer coil as claimed in any one of claims 1 to 9, and comprises the following steps:

s1: winding a half-turn coil

One coil passes through one window of the transformer magnetic core with two windows at a time to form a half-turn coil;

s2: winding the whole turn coil

Simultaneously passing the other coil through two windows on the magnetic core of the transformer at a time to form a whole-turn coil;

s3: connected into a half-turn structure

And sequentially connecting a half-turn coil and a plurality of whole-turn coils in series according to the transformer transformation ratio to form a half-turn structure.

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