CN111916270A

CN111916270A - Filtering transformer and manufacturing method thereof

Info

Publication number: CN111916270A
Application number: CN201910380754.7A
Authority: CN
Inventors: 潘詠民; 许汉正; 戴廷祐
Original assignee: Guangzhou Chenghan Electronic Technology Co ltd
Current assignee: Guangzhou Chenghan Electronic Technology Co ltd
Priority date: 2019-05-08
Filing date: 2019-05-08
Publication date: 2020-11-10

Abstract

A filter transformer device and a manufacturing method thereof, the filter transformer device comprises a winding main body and a lead unit, wherein the winding main body comprises a winding core, a first partition plate, a second partition plate, a third partition plate, a first partition plate, a second partition plate and a third partition plate, the first partition plate, the second partition plate and the third partition plate are sequentially and intermittently arranged on the winding core, the winding core is divided into a first winding part and a second winding part respectively, the first partition plate, the third partition plate and the third partition plate are respectively provided with at least one electrode, the lead unit comprises a first lead, a second lead, a conductive core part and an insulating outer covering part, the first lead and the second lead are wound around the first winding part in a first lead winding direction, the third lead is wound around the first winding part in a second lead winding direction, and crosses over the second partition plate to continuously wind the second winding part in the same winding direction as the second winding part. The manufacturing method can effectively simplify the winding operation to improve the production efficiency.

Description

Filtering transformer and manufacturing method thereof

Technical Field

The present invention relates to a transformer, and more particularly, to a filter transformer and a method for manufacturing the same.

Background

In the manufacturing process of the filter transformer composed of coils, the winding and fixing of the wires are basically completed by an automated machine, however, in the manufacturing process of the conventional filter transformer, if the filter transformer to be manufactured has more than three wires, and one winding core is divided into two winding parts by three partition plates, so that one winding part winds at least one wire to form a Common mode choke (Common mode hook) structure, the problems of complicated operation process and complicated machine control which affect the production efficiency due to the suspension of the winding process can be faced, and therefore, how to avoid the manufacturing process similar to the complexity is the future research direction.

Disclosure of Invention

The invention aims to provide a filter transformer device which solves the problems encountered by the existing manufacturing method and has innovative winding structure characteristics.

The invention provides a filtering and voltage transforming device, which comprises a winding main body and a lead unit, wherein the winding main body comprises a winding core, a first partition plate, a second partition plate and a third partition plate, the first partition plate, the second partition plate and the third partition plate are sequentially and alternately arranged on the winding core, the winding core is divided into a first winding part by the first partition plate and the second partition plate, the winding core is divided into a second winding part by the second partition plate and the third partition plate, the first partition plate and the third partition plate are respectively provided with a plurality of electrodes, and the second partition plate is provided with at least one electrode; the wire unit comprises a first wire, a second wire and a third wire, wherein each wire is provided with a core made of a conductor material and an outer coating which coats the core and is insulated.

The first lead and the second lead are wound together from the first separator to the third separator in a first lead winding direction, so that the first lead is wound around the first winding part and two ends of the core part of the first lead are respectively and electrically connected with one electrode of the first separator and one electrode of the second separator, the second lead is wound around the first winding part and continuously wound around the second winding part across the second separator, and two ends of the core part of the second lead are respectively and electrically connected with one electrode of the first separator and one electrode of the third separator; the third wire is wound around the first winding portion from the first separator toward the third separator in a second wire winding direction, and is wound across the second separator in the same winding direction as the second wire is wound around the second winding portion in the second winding direction, and both ends of the core portion thereof are electrically connected to one of the electrodes of the first separator and one of the electrodes of the third separator, respectively.

In the filtering transformer device of the present invention, the wire unit further includes a fourth wire, the fourth wire is wound around the first winding portion along the second wire winding direction from the first separator to the second separator, and two ends of the core of the fourth wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the second separator, respectively.

In the filtering transformer device of the present invention, the wire unit further includes a fifth wire, the fifth wire is wound around the second winding portion in the same winding direction as the second wire in the second winding portion from the first separator to the third separator, and two ends of the core of the fifth wire are electrically connected to one of the electrodes of the first separator or the second separator and one of the electrodes of the third separator, respectively.

In the filtering transformer device, the electrodes of the first partition plate, the second partition plate and the third partition plate are positioned on the same plane.

Another objective of the present invention is to provide a simpler manufacturing method for manufacturing the filtering transformer device, so as to solve the problems of complex machine control and low production line efficiency caused by the need of interrupting winding during the manufacturing process.

The invention provides a manufacturing method of a filtering transformer device, which comprises the following steps: (A) forming a winding main body, wherein the winding main body comprises a winding core, a first partition board, a second partition board and a third partition board, the first partition board, the second partition board and the third partition board are sequentially and alternately arranged on the winding core, the winding core is divided into a first winding part by the first partition board and the second partition board, the winding core is divided into a second winding part by the second partition board and the third partition board, and the first partition board, the second partition board and the third partition board are respectively provided with at least one electrode; (B) utilizing a first lead and a second lead to wind the first winding part in a first lead winding direction from the first partition to the third partition in the same direction, and the second lead crosses the second partition to continue to wind the second winding part; and (C) winding the first winding part with a third wire and a fourth wire in a second wire winding direction from the first partition plate to the third partition plate, wherein the third wire crosses the second partition plate and continues to wind the second winding part in the same winding direction as the second wire in the second winding part.

The manufacturing method of the filtering transformer device further comprises the following steps: (D) two ends of a core portion of the first lead are electrically connected to one of the electrodes of the first separator and one of the electrodes of the second separator, respectively; (E) two ends of a core portion of the second wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the third separator, respectively; (F) two ends of a core portion of the third wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the third separator, respectively; and (G) both ends of a core portion of the fourth wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the second separator, respectively.

The manufacturing method of the filtering transformer device further comprises the following steps: (H) and winding the second winding part in the same winding direction of the second lead in the second winding part by utilizing the direction of a fifth lead from the first partition plate to the third partition plate.

The manufacturing method of the filtering transformer device further comprises the following steps: (I) one end of a core portion of the fifth wire is electrically connected to one of the electrodes of the first separator or the second separator, and the other end of the core portion of the fifth wire is electrically connected to one of the electrodes of the third separator.

The invention has the beneficial effects that: the filtering transformer device is manufactured by the manufacturing method, so that any one wire is wound to the bottom in the manufacturing process, and the winding operation is effectively simplified to improve the production efficiency.

Drawings

Other features and effects of the present invention will become apparent from the following detailed description of the embodiments with reference to the accompanying drawings, in which:

fig. 1 is a bottom view illustrating a first embodiment of the filter transformer apparatus of the present invention;

FIG. 2 is a flow chart illustrating the manufacturing process of the first embodiment;

fig. 3 is a partial sectional view illustrating a wire lap state of the first embodiment;

fig. 4 is a bottom view illustrating a second embodiment of the filter transformer apparatus of the present invention;

FIG. 5 is a flow chart illustrating the manufacturing process of the second embodiment;

fig. 6 is a partial sectional view illustrating a wire lap state of the second embodiment;

fig. 7 is a bottom view illustrating a third embodiment of the filter transformer apparatus of the present invention; and

fig. 8 is a partial sectional view illustrating a wire winding state of the third embodiment.

Detailed Description

Before the present invention is described in detail, it should be noted that in the following description, similar components are denoted by the same reference numerals.

Referring to fig. 1, a first embodiment of a filter transformer apparatus according to the present invention includes a winding body 3 and a wire unit 4, the winding body 3 includes a winding core 31, a first partition 32 disposed at one end of the winding core 31, a second partition 33 disposed at the winding core 31, and a third partition 34 disposed at the other end of the winding core 31, the second partition 33 is disposed between the first partition 32 and the third partition 34, and the first partition 32, the second partition 33, and the third partition 34 are sequentially and alternately disposed at the winding core 31 to divide the winding core 31 into a first winding portion 311 and a second winding portion 312.

The winding body 3 may be an integrally formed iron structure, or may be a combination structure of the winding core 31 and three Flange (Flange) plates respectively serving as the first partition 32, the second partition 33, and the third partition 34, the winding core 31 may be a strip-shaped iron core or other metal material, in this embodiment, the winding core 31 is a strip-shaped iron core with a square cross section, the first partition 32, the second partition 33, and the third partition 34 are all square Flange plates with the same size (length/width/height), the winding body 3 is assembled by the winding core 31, the first partition 32, the second partition 33, and the third partition 34, but not limited thereto, and a side area of each partition is larger than a cross section area of the winding core 31.

The first electrode P1, the second electrode P2, and the third electrode P3 are disposed on a circumferential surface of the first separator 32, the fourth electrode P4 is disposed on a circumferential surface of the second separator 33, the fifth electrode P5 and the sixth electrode P6 are disposed on a circumferential surface of the third separator 34, the circumferential surface of the first separator 32, the circumferential surface of the second separator 33, and the circumferential surface of the third separator 34 are all at the same level, so that the first electrode P1 to the sixth electrode P6 are soldered to a system circuit board.

The conducting wire unit 4 includes a first conducting wire 41, a second conducting wire 42, a third conducting wire 43, and a fourth conducting wire 44, each conducting wire has a core made of a conductive material and an outer covering portion covering the core and insulated from the core, in this embodiment, the core of each conducting wire is a copper wire, and the outer covering portion is an electroplating insulator covering the copper wire, but not limited thereto.

The end of the winding core 31 connected to the first partition 32 is defined as a first winding end, the other end of the winding core 31 connected to the third partition 34 is defined as a second winding end, and the direction from the first winding end to the second winding end is defined as a winding direction.

One end of the first conducting wire 41 and one end of the second conducting wire 42 are electrically connected to the first electrode P1 and the third electrode P3, respectively, and are co-wound around the first winding portion 311 counterclockwise along the winding direction until the other end of the first conducting wire 41 is electrically connected to the fourth electrode P4, and the second conducting wire 42 crosses the second partition 33 and continues to be wound around the second winding portion 312 counterclockwise along the winding direction until the other end of the second conducting wire 42 is electrically connected to the fifth electrode P5.

It should be noted that the co-winding of the plurality of wires may be side-by-side, overlapped, or spaced, and in this embodiment, the co-winding refers to the co-winding of the plurality of wires.

One end of the third conductive wire 43 and one end of the fourth conductive wire 44 are electrically connected to the second electrode P2 and the third electrode P3, respectively, and are wound around the first winding portion 311 clockwise along the winding direction until the other end of the third conductive wire 43 is electrically connected to the fourth electrode P4, and the fourth conductive wire 44 crosses the second partition 33 and continues to wind around the second winding portion 312 along the winding direction but in the counterclockwise direction until the other end of the fourth conductive wire 44 is electrically connected to the sixth electrode P6.

Referring to fig. 2, a manufacturing process of the filter transformer apparatus of the first embodiment includes a first manufacturing step 501 to a seventh manufacturing step 507.

In the first manufacturing step 501, the assembling machine assembles the winding core 31, the first partition 32, the second partition 33, and the third partition 34 into the winding body 3, and then enters the second manufacturing step 502.

In the second manufacturing step 502, the winding machine winds the first conductive wire 41 and the second conductive wire 42 around the first winding portion 311 counterclockwise along the winding direction, and winds the second conductive wire 42 around the second winding portion 312 counterclockwise along the winding direction across the second partition 33, and then proceeds to the third manufacturing step 503.

In the third step 503, the bonding machine electrically connects the two ends of the core of the first conductive wire 41 to the first electrode P1 and the fourth electrode P4, respectively, and then proceeds to the fourth step 504.

In the fourth step 504, a bonding machine electrically connects the two ends of the core of the second conductive wire 42 to the third electrode P3 and the fifth electrode P5, respectively, and then proceeds to the fifth step 505.

In the fifth step 505, the winding machine winds the third conductive wire 43 and the fourth conductive wire 44 clockwise around the first winding portion 311 along the winding direction, and the fourth conductive wire 44 crosses the second partition 33 and continues to wind the second winding portion 312 along the winding direction but in the counterclockwise direction, and then the process proceeds to the sixth step 506.

In the sixth step 506, the bonding machine electrically connects the two ends of the core of the third conductive wire 43 to the second electrode P2 and the fourth electrode P4, respectively, and then proceeds to the seventh step 507.

In step seven 507, a bonding machine electrically connects the two ends of the core of the fourth conductive wire 44 to the third electrode P3 and the sixth electrode P6, respectively, and then the manufacturing process is terminated.

Referring to fig. 3, in the filter transformer apparatus manufactured by the manufacturing process, the first layer coil of the first winding portion 311, i.e., the bottom coil, is wound around the winding core 31 by the first conductive wire 41 and the second conductive wire 42, and the second layer coil of the first winding portion 311 is wound by the third conductive wire 43 and the fourth conductive wire 44 and is overlapped on the first conductive wire 41 and the second conductive wire 42. The first layer coil, i.e., the lowermost coil, of the second winding part 312 is wound around the winding core 31 by the second wire 42, and the second layer coil of the second winding part 312 is wound around the second wire 42 by the fourth wire 44.

In a different embodiment, the first conductive wire 41 and the second conductive wire 42 can be wound around the first winding portion 311 clockwise along the winding direction, the third conductive wire 43 and the fourth conductive wire 44 can be wound around the first winding portion 311 counterclockwise along the winding direction, the second conductive wire 42 crosses the second partition 33 and continues to wind around the second winding portion 312 clockwise along the winding direction, and the fourth conductive wire 44 crosses the second partition 33 and continues to wind around the second winding portion 312 clockwise along the winding direction.

In another different embodiment, the first conductive wire 41 and the second conductive wire 42 can be wound around the first winding portion 311 clockwise along the winding direction, the third conductive wire 43 and the fourth conductive wire 44 can be wound around the first winding portion 311 counterclockwise along the winding direction, the second conductive wire 42 crosses the second partition 33 and continues to wind around the second winding portion 312 counterclockwise along the winding direction, and the fourth conductive wire 44 crosses the second partition 33 and continues to wind around the second winding portion 312 counterclockwise along the first winding direction.

That is, as long as the winding direction of the first conductive line 41 and the second conductive line 42 in the first winding part 311 is opposite to the winding direction of the third conductive line 43 and the fourth conductive line 44 in the first winding part 311, and the second conductive line 42 and the fourth conductive line 44 are wound in the same direction on the second winding part 312, the transformer of the present embodiment can be formed, even if the third conductive line 43 and the fourth conductive line 44 are wound first and then the first conductive line 41 and the second conductive line 42 are wound, the transformer has a similar transformer effect, and since the winding direction of the first conductive line 41 and the second conductive line 42 in the first winding part 311 is opposite to the winding direction of the third conductive line 43 and the fourth conductive line 44 in the first winding part 311, the primary side of the transformer has a phase difference, and a better signal transmission characteristic is achieved.

A simplified implementation of the present embodiment may be that only the first conductive line 41, the second conductive line 42, and the fourth conductive line 44 are provided, except that the third conductive line 43 is omitted, so that the simplified implementation does not have a secondary-side center tap, but still has a simpler manufacturing process compared to the conventional filter transformer which is also a three-conductive line manufacturing process.

Referring to fig. 4, a second embodiment of the filtering transformer apparatus of the present invention is similar to the first embodiment, except that the second partition 33 is further provided with a seventh electrode P7, the third partition 34 is further provided with an eighth electrode P8, the wire unit 4 further includes a fifth wire 45, one end of the fifth wire 45 is electrically connected to the seventh electrode P7, and the fifth wire 45 is wound around the second winding portion 312 along the winding direction in a counterclockwise direction until the other end of the fifth wire 45 is electrically connected to the eighth electrode P8.

Referring to fig. 5, a manufacturing process of the filter transformer apparatus of the second embodiment is similar to that of the first embodiment, except that the manufacturing process of this embodiment further includes a manufacturing step eight 508 and a manufacturing step nine 509, and after completing the steps one 501 to seven 507, the process proceeds to the step eight 508.

In the eighth step 508, the winding machine winds the fifth conductive wire 45 around the second winding portion 312 counterclockwise along the winding direction, and then proceeds to the ninth step 509.

In the ninth step 509, a welding machine electrically connects the two ends of the core of the fifth wire 45 to the seventh electrode P7 and the eighth electrode P8, respectively, and then the manufacturing process is terminated.

Referring to fig. 6, the filter transformer apparatus manufactured by the manufacturing process is different from the filter transformer apparatus of the first embodiment in that the third layer of the coil of the second winding portion 312 is formed by the fifth wire 45 being wound on the fourth wire 44 to form an inductor of the center tap of the secondary side.

It should be noted that, similar to the first embodiment and the different embodiments that can be extended therefrom, as long as the winding direction of the first conductive wire 41 and the second conductive wire 42 on the first winding portion 311 is opposite to the winding direction of the third conductive wire 43 and the fourth conductive wire 44 on the first winding portion 311, and the second conductive wire 42, the fourth conductive wire 44, and the fifth conductive wire 45 are wound on the second winding portion 312 in the same direction, the filtering transformer apparatus of the present embodiment can be formed.

Referring to fig. 7, a third embodiment of the filtering transformer apparatus of the present invention is similar to the second embodiment, except that: the first conductive wire 41, the second conductive wire 42, the third conductive wire 43, and the fourth conductive wire 44 are aligned and wound around the first winding portion 311 in the same direction (counterclockwise direction along the winding direction); second, the seventh electrode P7 electrically connected to the fifth wire 45 is disposed on the first separator 32 and adjacent to the third electrode P3, so that when the third electrode P3 is electrically connected to the seventh electrode P7 to form a center tap, it can be connected by spot welding without pulling another wire; third, the second conductive line 42, the fourth conductive line 44, and the fifth conductive line 45 are wound around the second winding portion 312 in parallel and aligned, so that only one conductive line layer is formed on the second winding portion 312, as shown in fig. 8.

It should be noted that, in the filtering transformer of the present embodiment, the first conductive line 41, the second conductive line 42, the third conductive line 43, and the fourth conductive line 44 are wound in the same direction, so that the primary side of the filtering transformer has no phase difference, and therefore the signal transmission characteristic of the filtering transformer is inferior to that of the filtering transformer of the second embodiment, but the filtering transformer can still achieve the function of filtering transformation.

In a different embodiment, the first conductive line 41, the second conductive line 42, the third conductive line 43, and the fourth conductive line 44 are alternately wound around the first winding portion 311 in another direction (clockwise along the winding direction) at intervals, so as to form a plurality of conductive line layers on the first winding portion 311, and the plurality of conductive line layers do not present a specific conductive line sequence or a specific conductive line. The second wires 42, the fourth wires 44, and the fifth wires 45 are wound around the second winding portion 312 at intervals, so as to form a plurality of wire layers on the second winding portion 312, and the plurality of wire layers do not exhibit a specific wire sequence or a specific wire, as long as the second wires 42, the fourth wires 44, and the fifth wires 45 are wound in the same direction.

It should be noted that, similar to the second embodiment and the different embodiments that can be extended therefrom, as long as the first conductive line 41, the second conductive line 42, the third conductive line 43 and the fourth conductive line 44 are wound in the same direction at the first winding portion 311, and the second conductive line 42, the fourth conductive line 44 and the fifth conductive line 45 are wound in the same direction at the second winding portion 312, the filter transformer apparatus of the present embodiment can be formed.

In summary, the filtering transformer and the manufacturing method thereof according to the present invention wind the first winding portion 311 through the second conductive wire 42 and the fourth conductive wire 44 in the winding direction, and then continue to wind the second winding portion 312 uninterruptedly, so as to effectively solve the problem that the winding needs to be interrupted in the conventional manufacturing method, thereby achieving the purpose of the filtering transformer and the manufacturing method thereof.

The above description is only an example of the present invention, and the scope of the present invention should not be limited thereby, and the invention is still within the scope of the present invention by simple equivalent changes and modifications made according to the claims and the contents of the specification.

Claims

1. A filtering transformer device is characterized in that: comprises the following steps:

the winding main body comprises a winding core, a first partition board, a second partition board and a third partition board, wherein the first partition board, the second partition board and the third partition board are sequentially and alternately arranged on the winding core, the winding core is divided into a first winding part by the first partition board and the second partition board, the winding core is divided into a second winding part by the second partition board and the third partition board, the first partition board and the third partition board are respectively provided with a plurality of electrodes, and the second partition board is provided with at least one electrode; and

the wire unit comprises a first wire, a second wire and a third wire, wherein each wire is provided with a core made of a conductor material and an outer coating which coats the core and is insulated;

the first lead and the second lead are wound together from the first clapboard to the direction of the third clapboard in a first lead winding direction, so that the first lead is wound around the first winding part and two tail ends of a core part of the first lead are respectively and electrically connected with one electrode of the first clapboard and one electrode of the second clapboard, the second lead is wound around the first winding part and continuously wound around the second winding part across the second clapboard, and two tail ends of the core part of the second lead are respectively and electrically connected with one electrode of the first clapboard and one electrode of the third clapboard;

the third wire is wound around the first winding portion from the first separator toward the third separator in a second wire winding direction, and is wound across the second separator in the same winding direction as the second wire is wound around the second winding portion in the second wire winding direction, and both ends of the core of the third wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the third separator, respectively.

2. The filter transformer apparatus of claim 1, wherein: the wire unit further comprises a fourth wire, the fourth wire is wound around the first winding portion along the second wire winding direction from the first separator to the second separator, and two ends of a core of the fourth wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the second separator, respectively.

3. The filter transformer apparatus of claim 2, wherein: the wire unit further includes a fifth wire wound around the second winding portion in the same winding direction as the second wire in the second winding portion from the first separator toward the third separator, and both ends of a core of the fifth wire are electrically connected to one of the electrodes of the first separator or the second separator and one of the electrodes of the third separator, respectively.

4. The filter transformer apparatus of claim 1, wherein: the electrodes of the first separator, the second separator and the third separator are on the same plane.

5. A manufacturing method of a filtering transformer device is characterized in that: comprises the following steps:

(A) forming a winding main body, wherein the winding main body comprises a winding core, a first partition board, a second partition board and a third partition board, the first partition board, the second partition board and the third partition board are sequentially and alternately arranged on the winding core, the winding core is divided into a first winding part by the first partition board and the second partition board, the winding core is divided into a second winding part by the second partition board and the third partition board, and the first partition board, the second partition board and the third partition board are respectively provided with at least one electrode;

(B) utilizing a first lead and a second lead to wind the first winding part in the same direction from the first partition to the third partition in the first lead winding direction, wherein the second lead crosses the second partition to continue winding the second winding part; and

(C) and a third lead and a fourth lead are utilized to wind the first winding part from the first clapboard to the third clapboard in a second lead winding direction, and the third lead crosses the second clapboard to continue to wind the second winding part in the same winding direction of the second lead on the second winding part.

6. The method of manufacturing a filter transformer apparatus according to claim 5, wherein: further comprises the following steps

(D) Two ends of a core portion of the first lead are electrically connected to one of the electrodes of the first separator and one of the electrodes of the second separator, respectively;

(E) two ends of a core portion of the second wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the third separator, respectively;

(F) two ends of a core portion of the third wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the third separator, respectively; and

(G) both ends of a core portion of the fourth wire are electrically connected to one of the electrodes of the first separator and one of the electrodes of the second separator, respectively.

7. The method of manufacturing a filter transformer apparatus according to claim 6, wherein: also comprises the following steps of,

(H) and winding the second winding part in the same winding direction of the second lead in the second winding part by utilizing the direction of a fifth lead from the first partition plate to the third partition plate.

8. The method of manufacturing a filter transformer apparatus according to claim 7, wherein: also comprises the following steps of,

(I) one end of a core portion of the fifth wire is electrically connected to one of the electrodes of the first separator or the second separator, and the other end of the core portion of the fifth wire is electrically connected to one of the electrodes of the third separator.