CN112086284A - Transformer rubber-coated metal winding and rubber coating method thereof - Google Patents
Transformer rubber-coated metal winding and rubber coating method thereof Download PDFInfo
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- CN112086284A CN112086284A CN202010919744.9A CN202010919744A CN112086284A CN 112086284 A CN112086284 A CN 112086284A CN 202010919744 A CN202010919744 A CN 202010919744A CN 112086284 A CN112086284 A CN 112086284A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2847—Sheets; Strips
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2871—Pancake coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Insulating Of Coils (AREA)
Abstract
The invention relates to a transformer rubber-coated metal winding and a rubber-coated method thereof, the invention forms a metal coil which can be assembled in a stacking way by stamping a metal sheet in a plane spiral way, increases the number of turns of the formed metal winding in a way of stacking and welding the metal coil, and forms the transformer rubber-coated metal winding in a way of injection molding and rubber coating at least twice on the metal winding, thereby solving the problem that the metal winding is difficult to position in a mould and the problem that the existing rubber-coated metal product cannot resist high pressure; because the transformer rubber-coated metal winding is injected with at least two plastic layers, the transformer rubber-coated metal winding has good insulating property, can bear high temperature and high pressure, and has good safety performance so as to meet the use requirement in a transformer and the safety requirement of UL 60950.
Description
Technical Field
The invention relates to the technical field of metal winding encapsulation, in particular to an encapsulated metal winding of a transformer capable of enduring high voltage and an encapsulating method thereof.
Background
At present, the encapsulated spiral metal windings are rarely applied to the transformer in the market, because most of the encapsulated metal products in the market are low-voltage or lower than 380V products, and basically most of the existing encapsulated metal products have no temperature grade requirement, the requirements of high temperature resistance and high voltage resistance of the transformer cannot be met. It is also worth mentioning that when the metal product is encapsulated by the existing metal encapsulating method, the metal product is difficult to position in an injection mold, especially, the thin metal sheet is difficult to position in the injection mold, so that the metal encapsulation is uncontrollable, the quality of the encapsulated metal product is poor, and short circuit can occur during injection due to metal displacement. Therefore, the encapsulated metal product obtained by the existing encapsulation mode has poor performance and a limited application range, and cannot be applied to a transformer. In other words, it is difficult to ensure that the obtained encapsulated metal product can withstand high temperature and high pressure by the existing metal encapsulation method, and it is also difficult to meet the safety requirements of UL 60950.
Disclosure of Invention
Based on this, an object of the present invention is to provide an encapsulated metal winding of a transformer capable of withstanding high temperature and high voltage and an encapsulating method thereof.
A method for encapsulating an encapsulated metal winding of a transformer comprises the following steps:
a. stamping at least two metal sheets to form two metal coils with at least one loop;
b. welding the two metal coils to obtain a metal winding;
c. placing the metal winding into an injection mold, and performing first injection molding to form a first plastic layer so as to fix the metal winding; and
d. and forming a second plastic layer through second injection molding, and wrapping and covering the metal winding by the second plastic layer and the first plastic layer to obtain the transformer rubber-coated metal winding.
In one embodiment of the present invention, in the step (a), the metal coils which can be assembled in a stacked manner are formed by punching the metal sheet in a planar spiral manner, wherein corresponding welding points are reserved at corresponding ends of each metal coil, and the number of turns of the metal winding is increased by stacking and welding the metal coils.
In an embodiment of the present invention, in the step (b), two metal coils are stacked in the fixture in a mirror image manner, and the two metal coils are welded by the corresponding welding points, so as to obtain the metal winding.
In an embodiment of the invention, a temperature-resistant adhesive tape layer or a polyester film isolation layer is disposed between the two metal coils.
In one embodiment of the present invention, in the step (b), the metal winding is formed to have two metal sheet pins and to have an operation space formed at a central position thereof.
In an embodiment of the invention, during the injection molding in the step (c), the metal winding is positioned through the operation space and the two metal sheet pins, wherein the first plastic layer formed by injection molding clamps and wraps the metal winding, and has a hollow column located in the operation space, a plurality of plastic ridges divergently extending from the hollow column, and positioning portions extending from the hollow column and wrapping the two metal sheet pins.
In an embodiment of the present invention, at least one step is formed at an edge portion of the first plastic layer formed by injection molding, and in the step (d), the second plastic layer formed by injection molding covers a portion of the metal winding that is not covered by the first plastic layer, and an edge portion of the second plastic layer covers the step combined with the first plastic layer.
In an embodiment of the invention, the thickness of the injection-molded transformer encapsulated metal winding is greater than or equal to 0.4mm, so that the requirement of safety regulations can be met.
The invention also provides a transformer encapsulated metal winding, which is prepared by the encapsulating method of the transformer encapsulated metal winding.
According to the invention, the metal winding is formed by mirror-image stacking and welding of two metal coils with opposite winding directions, and the transformer rubber-coated metal winding is formed by at least twice injection molding and rubber coating of the metal winding, so that the operation steps are simple, the realization is simple, the problem that the metal winding is difficult to position in a mold is solved, and the problem that the existing rubber-coated metal product is not high-pressure resistant is solved. The transformer rubber-coated metal winding is injected with at least two plastic layers, so that the transformer rubber-coated metal winding has good insulating property, can resist high temperature and high pressure, and has good safety performance so as to meet the use requirement in a transformer and the safety requirement of UL 60950.
According to the invention, the metal winding can be completely wrapped by a thinner plastic layer through a mode of forming the plastic layer by at least two layers of injection molding, and the insulating property of the plastic layer is ensured through a plurality of plastic layers, so that the transformer encapsulated metal winding can bear high temperature and high pressure and meet the safety requirements of UL 60950.
On one hand, when the second plastic layer is formed by injection molding, the bonding area between the first plastic layer and the second plastic layer can be increased, the bonding stability between the first plastic layer and the second plastic layer is ensured, and the problem of bonding between the plastic layers is solved; on the other hand, the creepage distance of the transformer encapsulated metal winding is increased by one or more step pieces, so that the transformer encapsulated metal can withstand high voltage.
The invention obtains the metal winding by the mode of stamping the metal sheet to form two metal coils with at least one loop and the mode of welding the two metal coils through the corresponding welding points, so that the metal winding is provided with the operation space and two metal sheet pins, the metal winding is positioned in an injection mold by utilizing the operation space and the two metal sheet pins, the metal winding is positioned by the operation space positioned at the central position of the metal winding, plastic can be accurately injected at the central position of the metal winding, and the position of the metal winding is fixed by positioning through the two metal sheet pins, the metal winding can be prevented from moving during injection molding, and the problem that the thin metal sheet is difficult to position in the injection mold is solved, the injection molding controllability of the metal winding is improved, the encapsulation speed of the transformer encapsulated metal winding is improved, and the encapsulation quality of the transformer encapsulated metal winding is ensured. According to the transformer encapsulated metal winding, the insulating property of the formed metal winding is ensured by arranging the temperature-resistant adhesive tape layer or the polyester film isolating layer between the two metal coils, the number of turns of the metal winding can be increased by forming the metal winding in a mode of mirror-image stacking and welding the two metal coils with opposite winding directions, the height of the metal winding can be reduced, and the height of the transformer encapsulated metal winding can be reduced, so that the use requirement of the transformer encapsulated metal winding on the transformer can be met.
Further objects and advantages of the invention will be fully apparent from the ensuing description and drawings.
Drawings
Fig. 1 is a flow chart of a method for encapsulating a transformer encapsulated metal winding according to a preferred embodiment of the invention.
Fig. 2 is a schematic step diagram of the method for encapsulating the transformer encapsulated metal winding according to the above preferred embodiment of the invention, which illustrates a forming flow of the metal winding.
Fig. 3 is a schematic step diagram of the method for encapsulating the transformer encapsulated metal winding according to the above preferred embodiment of the invention, which illustrates the specific structure of the metal winding.
Fig. 4 is a schematic step diagram of the method for encapsulating the transformer encapsulated metal winding according to the above preferred embodiment of the invention, which illustrates the structure of the injection-molded first plastic layer.
Fig. 5 is a schematic step diagram of the method for encapsulating the transformer encapsulated metal winding according to the above preferred embodiment of the invention, which illustrates the structure of the second plastic layer formed by injection molding.
The reference numbers illustrate: transformer rubber-coated metal winding 10; a metal sheet 11; a metal coil 111; a solder joint 112; a metal winding 12; an operating space 120; a sheet metal pin 121; a first plastic layer 13; a hollow column 130; a plastic ridge 131; a positioning portion 132; a step piece 133; a second plastic layer 14.
Detailed Description
The following description is presented to disclose the invention so as to enable any person skilled in the art to practice the invention. The preferred embodiments in the following description are given by way of example only, and other obvious variations will occur to those skilled in the art. The basic principles of the invention, as defined in the following description, may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.
It will be understood by those skilled in the art that in the present disclosure, the terms "vertical," "lateral," "up," "down," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in the orientation or positional relationship indicated in the drawings for ease of description and simplicity of description, and do not indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and thus, the above terms should not be construed as limiting the present invention.
It is understood that the terms "a" and "an" should be interpreted as meaning that a number of one element or element is one in one embodiment, while a number of other elements is one in another embodiment, and the terms "a" and "an" should not be interpreted as limiting the number.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; may be mechanically connected, may be electrically connected or may be in communication with each other; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
As shown in fig. 1 to 5, a detailed structure of a transformer encapsulated metal winding 10 and an encapsulating method thereof according to a preferred embodiment of the present invention are specifically illustrated.
As shown in fig. 1, the method for encapsulating the transformer encapsulated metal winding 10 comprises the following steps:
a. stamping at least two metal sheets 11 to form two metal coils 111 with at least one loop;
b. welding the two metal coils 111 to obtain a metal winding 12;
c. placing the metal winding 12 into an injection mold, and performing first injection molding to form a first plastic layer 13 so as to fix the metal winding 12; and
d. and forming a second plastic layer 14 through second injection molding, and wrapping and covering the metal winding 12 by the second plastic layer 14 and the first plastic layer 13 to obtain the transformer encapsulated metal winding 10.
It is worth mentioning that, as shown in fig. 2, in the step (a), the metal sheet 11 is punched by a planar spiral manner to form the metal coils 111 that can be assembled in a stacked manner, wherein corresponding welding points 112 are reserved on corresponding ends of each metal coil 111, and the number of turns of the metal winding 12 is increased by stacking and welding the metal coils 111.
As shown in fig. 2, the two punched metal coils 111 have opposite winding directions, and a corresponding welding point 112 is reserved at a corresponding end of each metal coil 111.
Further, in the step (b), two metal coils 111 are mirror-stacked in the fixture, and the two metal coils 111 are welded by the corresponding welding points 112, so as to obtain the metal winding 12.
It is worth mentioning that a temperature-resistant adhesive tape layer or a polyester film isolation layer is arranged between the two metal coils 111 to ensure the obtained insulation performance of the metal winding 12, and the number of turns of the metal winding 12 can be increased by stacking the two metal coils 111 in a jig in a mirror image manner for welding, and the height of the formed metal winding 12 can be reduced, which is beneficial to reducing the height of the transformer encapsulated metal winding 10 to meet the use requirement of the transformer encapsulated metal winding on the transformer.
Specifically, as shown in fig. 3, in the step (b), the metal winding 12 has two metal sheet pins 121 and is formed with an operation space 120 at a central position thereof; during injection molding, the metal winding 12 is positioned via the operating space 120 and the two sheet metal pins 121.
It is understood that the present invention obtains the metal winding 12 by stamping the metal sheet 11 to form two metal coils 111 having at least one loop and welding the two metal coils 111 through the corresponding welding points 112, so that the metal winding 12 has the operation space 120 and two metal sheet pins 121.
Further, as shown in fig. 4, in the step (c), the first plastic layer 13 formed by injection molding clamps and wraps the metal winding 12, and has a hollow column 130 located in the operating space, a plurality of plastic ridges 131 divergently extending from the hollow column 130, and a positioning portion 132 extending from the hollow column 130 and wrapping the two metal sheet pins 121.
It can be understood that the metal winding 12 is formed by mirror-image stacking and welding the metal coil 111, so that the metal winding 12 has the operation space 120 and two spaced metal sheet pins 121, and the metal winding 12 can be positioned by using the operation space 120 and two spaced metal sheet pins 121 during injection molding, i.e. positioning of the metal winding 12 in an injection mold is facilitated. Specifically, positioning the metal winding 12 through the operation space located at the center of the metal winding 12 enables plastic to be accurately injected at the center of the metal winding 12, and positioning is performed through the two metal sheet pins 121, so that the position of the metal winding 12 is fixed, the metal winding 12 can be prevented from moving during injection molding, the problem that the thin metal sheet 11 is difficult to position in an injection mold is solved, the injection molding controllability of the metal winding 12 is improved, the encapsulation rate of the transformer encapsulated metal winding 10 is improved, and the encapsulation quality of the transformer encapsulated metal winding 10 is ensured.
It can be further understood that, after the first plastic layer 13 is formed by injection molding, the metal winding 12 is wrapped and positioned by the first plastic layer 13, so that the injection molding encapsulation operation of the second plastic layer 14 can be facilitated, that is, the problem that the metal winding 12 is difficult to position in an injection mold can be solved by means of multiple injection encapsulation, and the thickness of the plastic layer can be increased, so that the insulation performance and the voltage resistance performance of the transformer encapsulated metal winding 10 can be ensured.
Further, as shown in fig. 5, in the step (d), the second plastic layer 14 covers a portion of the metal winding 12 not covered by the first plastic layer 13, and an edge portion thereof covers and is bonded to an edge portion of the first plastic layer 13.
In particular, the edge portion of the first plastic layer 13 formed by injection molding is formed with at least one step 133 to increase the bonding area of the first plastic layer 13 and the second plastic layer 14 when the second plastic layer 14 is injection molded.
It can be understood that the edge portion of the first plastic layer 13 of the transformer encapsulated metal winding 10 is formed with at least one step 133, and on one hand, when the second plastic layer 14 is formed by injection molding, the step 133 can increase the bonding area between the first plastic layer 13 and the second plastic layer 14, ensure the stability of the bonding between the first plastic layer 13 and the second plastic layer 14, and solve the problem of the bonding between the plastic layers; on the other hand, the creepage distance of the transformer encapsulated metal winding 10 is increased through the one or more step pieces 133, which is beneficial to enhancing the voltage resistance of the transformer encapsulated metal, so that the transformer encapsulated metal can be applied to a transformer and can meet the safety requirements of UL 60950.
It is worth mentioning that the thickness of the transformer encapsulated metal winding 10 formed by injection molding is greater than or equal to 0.4mm, so as to ensure the voltage resistance of the transformer encapsulated metal winding 10 and to meet the safety requirements of UL 60950.
It should be understood that the method of encapsulating the transformer encapsulated metal winding 10 of the present invention may include multiple times of injection molding encapsulation to form the transformer encapsulated metal winding 10, i.e., the present invention is not limited to the number of times of injection molding. It can be understood that the present invention forms the metal winding 12 by stacking and welding two metal coils 111 with opposite winding directions in a mirror image manner, and forms the transformer encapsulated metal winding 10 by at least twice injection molding encapsulation on the metal winding 12, the operation steps are simple, the implementation is easy, the problem that the metal winding 12 is difficult to position in a mold is solved, and the problem that the existing encapsulated metal product is not resistant to high voltage is solved. Because the transformer rubber-coated metal winding 10 is injected with at least two plastic layers, the transformer rubber-coated metal winding has good insulating property, can bear high temperature and high pressure, and has good safety performance so as to meet the use requirement in a transformer and the safety requirement of UL 60950.
According to the method, the metal winding 12 can be completely wrapped by a thin plastic layer through a mode of forming the plastic layer by at least two layers of injection molding, and the insulating property of the plastic layer is ensured through a plurality of plastic layers, so that the transformer encapsulated metal winding 10 can bear high temperature and high pressure and can meet the safety requirements of UL60950, and therefore the method for encapsulating the transformer encapsulated metal winding 10 is low in production cost and high in safety.
The technical features of the above embodiments can be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the above embodiments are not described, but should be considered as the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above examples only express preferred embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (9)
1. The method for encapsulating the transformer encapsulated metal winding is characterized by comprising the following steps of:
a. stamping at least two metal sheets to form two metal coils with at least one loop;
b. welding the two metal coils to obtain a metal winding;
c. placing the metal winding into an injection mold, and performing first injection molding to form a first plastic layer so as to fix the metal winding; and
d. and forming a second plastic layer through second injection molding, and wrapping and covering the metal winding by the second plastic layer and the first plastic layer to obtain the transformer rubber-coated metal winding.
2. The method of claim 1, wherein in step (a), the metal coils are formed by punching the metal sheets in a planar spiral manner to be assembled in a stack, wherein corresponding welding points are reserved at corresponding ends of each of the metal coils, and the number of turns of the metal windings is increased by stack-welding the metal coils.
3. The method according to claim 2, wherein in step (b), two of said metal coils are stacked in a jig in a mirror image manner, and the two metal coils are welded by corresponding said welding points, thereby obtaining said metal winding.
4. The method of claim 2, wherein a temperature resistant tape layer or a mylar barrier layer is disposed between the two metal coils.
5. The method according to any one of claims 1 to 4, wherein in the step (b), the metal winding is formed to have two sheet metal pins and to have an operation space formed at a central position thereof.
6. The method of claim 5, wherein during the step (c), the metal winding is positioned via the operating space and the two sheet metal pins, wherein the first plastic layer is formed by injection molding to clamp and wrap the metal winding and has a hollow column located in the operating space, a plurality of plastic ridges divergently extending from the hollow column, and positioning portions extending from the hollow column and wrapping the two sheet metal pins.
7. The method according to claim 6, wherein the first plastic layer is formed by injection molding to have at least one step, and in the step (d), the second plastic layer is formed by injection molding to cover the portion of the metal winding not covered by the first plastic layer, and has an edge portion covering the step bonded to the first plastic layer.
8. The method of any of claims 1 to 4, wherein the injection molded transformer encapsulated metal winding has a thickness of 0.4mm or greater.
9. Transformer encapsulated metal winding, characterized in that it is produced by the method of encapsulating transformer encapsulated metal windings according to any of claims 1-8.
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CN202010919744.9A CN112086284B (en) | 2020-09-04 | 2020-09-04 | Transformer rubber-coated metal winding and rubber coating method thereof |
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CN202010919744.9A CN112086284B (en) | 2020-09-04 | 2020-09-04 | Transformer rubber-coated metal winding and rubber coating method thereof |
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CN209015849U (en) * | 2018-09-06 | 2019-06-21 | 深圳市兴奕精密五金有限公司 | A kind of New charger transformer |
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JPS5637616A (en) * | 1979-09-05 | 1981-04-11 | Toshiba Electric Equip Corp | High voltage transformer |
EP0199280A2 (en) * | 1985-04-19 | 1986-10-29 | Siemens Aktiengesellschaft | Contacting metal covered plastic parts of a coil form |
JP2000164434A (en) * | 1998-11-30 | 2000-06-16 | Hitachi Ltd | Winding wire of stationary induction apparatus |
CN201348924Y (en) * | 2009-02-10 | 2009-11-18 | 田先平 | Planar transformer winding |
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CN209015849U (en) * | 2018-09-06 | 2019-06-21 | 深圳市兴奕精密五金有限公司 | A kind of New charger transformer |
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