Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a vertical shielding type pulse transformer which can effectively reduce the condition of device performance reduction caused by the magnetic flux leakage phenomenon and ensure the effective welding of the device in the mounting process.
The invention is realized by the following technical scheme:
a vertical shielding type pulse transformer comprises a winding magnetic core body and a magnetic shielding cover fixedly sleeved outside the winding magnetic core body;
the winding magnetic core body comprises a columnar magnetic core for winding a coil, a first magnetic circuit magnetic core and a second magnetic circuit magnetic core which are arranged at two ends of the columnar magnetic core, a plurality of electrode grooves are formed in the first magnetic circuit magnetic core and the second magnetic circuit magnetic core, electrodes are arranged in the electrode grooves and connected with outgoing lines of the winding coil, and guide grooves are formed in the outer wall of the magnetic shielding cover and used for guiding the end portions of the electrodes to the mounting surface of the pulse transformer.
Preferably, the side walls of the first magnetic circuit core and the second magnetic circuit core are higher than the side wall of the columnar magnetic core, one side of the electrode groove close to the columnar magnetic core is an inclined plane, the lower end of the inclined plane is flush with the surface of the columnar magnetic core, and the outgoing line of the winding coil is laid along the inclined plane and connected with the electrode.
Preferably, the edges and corners of the columnar magnetic core are rounded corners or straight chamfers.
Preferably, the cross section area of the columnar magnetic core is 1-4 mm 2 。
Preferably, four winding coils are wound on the columnar magnetic core;
the four winding coils are wound in two layers, the two winding coils on the same layer are wound in the same winding direction at intervals, and the winding directions of the upper and lower layers of winding coils are opposite.
Preferably, the attaching surface is an end surface of the magnetic shielding case.
Preferably, the guide groove is a groove arranged on the surface of the magnetic shielding case, the electrode plate is laid in the groove, one end of the electrode plate is fixedly connected with the electrode groove, and the other end of the electrode plate is positioned in the groove of the attaching surface.
Preferably, the magnetic shielding case is a rectangular hollow tube with two open ends.
Preferably, the magnetic shield and the magnetic core body are both ferrite materials.
Preferably, the axial cross section of the wound magnetic core body is in an i shape.
Compared with the prior art, the invention has the following beneficial technical effects:
the invention provides a vertical shielding type pulse transformer, which comprises a winding magnetic core body and a magnetic shielding cover sleeved on the winding magnetic core body, wherein the magnetic shielding cover of a hollow magnetic tube is adopted to replace the existing magnetic cover plate, so that the capturing capability of a magnetic field generated by a coil when a device works is increased, the actual performance of the device is improved, and meanwhile, the influence of an electromagnetic field generated when the device works on surrounding devices can be reduced. The totally-enclosed magnetic core shield has certain rigidity, so that the inner coil can be protected from being extruded by external force or damaged by foreign objects in the transportation or actual use process, and the reliability of the device in actual use is effectively improved; secondly, in consideration of problems occurring during the actual use of the conventional plating electrode, an electrode pad is used instead of the conventional plating electrode. Compared with the traditional electroplating electrode, the electrode plate is partially exposed on the side surface, so that the working condition of each winding can be tested by directly using the electrode plate, a testing part is not required to be additionally arranged on the welding circuit board, and the design difficulty and the production cost are reduced. Meanwhile, the design of the electrode plate is more beneficial to subsequent mounting, and compared with the traditional coated electrode, the electrode plate can better adsorb and guide welding materials such as soldering tin and the like, so that insufficient soldering and desoldering are not easy to occur, and the reliability of the device in the actual use process can be well ensured.
Detailed Description
The present invention will now be described in further detail with reference to the attached drawings, which are illustrative, but not limiting, of the present invention.
As shown in fig. 1-3, a vertical shielded pulse transformer includes a wound core body and a magnetic shield case 1 fixedly sleeved outside the wound core body.
The winding magnetic core body comprises a columnar magnetic core 3 used for winding coils, a first magnetic circuit magnetic core 2 and a second magnetic circuit magnetic core 4 which are arranged at two ends of the columnar magnetic core, electrodes are arranged on the first magnetic circuit magnetic core 2 and the second magnetic circuit magnetic core 4, four winding coils are wound on the columnar magnetic core 3, and the winding coils are connected with the electrodes.
The two ends of the columnar magnetic core 3 are connected with the first magnetic circuit magnetic core 2 and the second magnetic circuit magnetic core 4 in a welding mode, and form an I-shaped structure, the joint of two adjacent side walls of the columnar magnetic core 3 is designed to be a round angle, so that the coil is reduced to be subjected to smaller abrasion in the winding process, a winding window is shown in figure 4 and is shaped into a rectangular window processed by the round angle, and the radius of the round angle is 0.03-0.2mm, so that when the mould is ensured to be convenient to install, the coil can be ensured not to pass through sharp edges and corners in the winding process to protect a coil insulating layer, and the reliability of a final product of the coil is improved.
Referring to fig. 2, two parallel sides of a first magnetic circuit core 2 and a second magnetic circuit core 4 are respectively provided with two electrode slots, the two electrode slots are arranged at intervals, one side of each electrode slot, which is close to a columnar magnetic core 3, is provided with an inclined plane, the lower end of each inclined plane is flush with the side wall of the columnar magnetic core 3, a winding coil can be wound on the magnetic core 3 of the columnar part and then laid into the electrode slots along the inclined planes to be connected with a motor, the electrode slots are arranged at the electrode positions to facilitate subsequent welding of electrode plates, meanwhile, the electrolysis slots are arranged at intervals, and protrusions between the two electrolysis slots can also play a role in isolating each electrode, so that the insulation characteristic of devices at the electrode positions is improved; secondly, the suspension condition of the coil when the coil is connected to the groove after the cylindrical magnetic core is wound is reduced by arranging the slope, and the space in which the coil can deform when the coil is subjected to external force is reduced, so that the reliability of the winding is improved, and the purpose of enhancing the reliability of a device is achieved.
The magnetic shielding case 1 is a magnetic tube with openings at two ends, the cross section of the magnetic tube is a rectangular ring, the magnetic shielding case is made of ferrite materials and is mainly used for sealing a magnetic circuit, improving the electrical performance of a finished device, protecting a coil from being damaged by external force and limiting the influence of an electromagnetic field generated by the device during working on surrounding devices. The whole body of the winding magnetic core is an I-shaped magnetic core, the material of the winding magnetic core is consistent with that of the magnetic shielding case 1, the winding magnetic core and the magnetic shielding case are bonded together through a magnetic adhesive, and the thickness of the adhesive in the finished product is preferably 50-80 microns.
The outer wall of the magnetic shielding case 1 is provided with a guide groove, the electrodes are arranged in the guide groove, the guide groove is used for guiding the electrodes of the first magnetic circuit magnetic core 2 and the second magnetic circuit magnetic core 4 to a mounting surface, and the mounting surface is positioned on the end surface of any end of the magnetic shielding case 1.
Referring to fig. 5 and 6, when the coil is wound on the cylindrical part magnetic core, four winding coils are wound in a vertical layered mode, and the directions of the upper winding coil and the lower winding coil are opposite, so that the purpose is to ensure that the magnetic fields induced by the two parts of coils are superposed but not offset after the upper winding coil and the lower winding coil are connected on the side of the second magnetic circuit magnetic core, and meanwhile, the condition that the coils are wound in the same direction when the winding starts and ends is ensured, the purpose is to reduce the functional requirements on an automatic winding machine when the subsequent automatic winding coils are wound, and the production cost is reduced.
Accordingly, considering the problems of the conventional plating electrode in practical use, for example: the welding condition of electrodes is inconvenient to observe on the welding surface, the cold joint is easy to remove, and the welding condition of devices and the like is inconvenient to directly test after welding. And SMT mounting requirements, electrode pads are selected to replace conventional plated electrodes. Compared with the traditional electroplating electrode, the electrode plate is partially exposed on the side surface, so that the working condition of each winding can be tested by directly using the electrode plate, a testing part is not required to be additionally arranged on the welding circuit board, and the design difficulty and the production cost are reduced. Meanwhile, the design of the electrode plate is more beneficial to subsequent mounting, and compared with the traditional coated electrode, the electrode plate can better adsorb and guide welding materials such as soldering tin and the like, so that insufficient soldering and desoldering are not easy to occur, and the reliability of the device in the actual use process can be well ensured.
In the design process of pulse transformer, the consideration to the magnetic core apron has mostly been ignored in current design, is limited to after increasing a magnetic core apron for the device only, guarantees the integrality of device induction magnetic field place magnetic circuit in the course of the work, but not all induction magnetic fields can both be caught by the magnetic core, consequently to the device, still has the magnetic leakage phenomenon of certain degree, leads to the device performance can't improve. In the invention, the cuboid magnetic core cover plate in the existing device is optimized into the magnetic shielding cover in the shape of the hollow magnetic tube, so that the capturing capacity of the magnetic field generated by the coil when the device works is increased, the actual performance of the device is improved, and the influence of the electromagnetic field generated when the device works on the surrounding devices can be reduced. And the totally enclosed magnetic core shield has certain rigidity, can protect the interior coil to receive the extrusion of external force or receive the destruction of foreign object in transportation or in-service use, the effectual reliability that improves the device in-service use.
Example 1
A vertical shielding type pulse transformer comprises a winding magnetic core body and a magnetic shielding cover 1 fixedly sleeved outside the winding magnetic core body; the winding magnetic core body comprises a columnar magnetic core 3 for winding a coil, and two ends of the columnar magnetic core 3 are respectively and fixedly connected with a first magnetic circuit magnetic core 2 and a second magnetic circuit magnetic core 4 to form an I-shaped winding magnetic core body.
As shown in fig. 2, in consideration of the purpose of improving the effective permeability of the magnetic core by using a rectangular parallelepiped magnetic core in the conventional transformer design, a certain magnetic leakage phenomenon still exists, which not only causes the performance of the device itself to greatly deviate from the design value, but also causes the device to form a large electromagnetic interference to the surrounding devices when the device operates. Meanwhile, the single cuboid magnetic core cover plate also means that the magnetic cores at two sides are exposed outside in the finished device, and if the finished device is extruded by large external force or collided by other articles in the mounting or manufacturing process, the insulating layer of the wound coil and even the structure of the coil are possibly damaged, so that the electrical function of the device is influenced. Therefore, the magnetic shielding cover in the embodiment is sleeved on the winding magnetic core body, so that the electrical performance of the device can be improved, the electromagnetic interference on surrounding devices is reduced, the reliability of the coil of the device in the using process can be ensured, and the normal work of the device is further ensured.
As shown in fig. 3, the wound core body includes a columnar core 3, a first magnetic-circuit core 2, and a second magnetic-circuit core 4. Eight grooves are arranged on the first magnetic circuit magnetic core 2 and the second magnetic circuit magnetic core 4, a first groove G1, a second groove G2, a third groove G3, a fourth groove G4, a fifth groove G5, a sixth groove G6, a seventh groove G7 and an eighth groove G8, wherein the second groove G2, the third groove G3, the sixth groove G6 and the seventh groove G7 are arranged on two sides of the first magnetic circuit magnetic core 2, and the first groove G1, the fourth groove G4, the fifth groove G5 and the eighth groove G8 are arranged on two sides of the second magnetic circuit magnetic core 4.
From fig. 3, one side that the recess is close to the column magnetic core is provided with inclined plane 5, and the lower extreme on inclined plane 5 and the lateral wall parallel and level of column magnetic core, inclined plane 5 effect are guaranteed that the winding can not appear the great unsettled state of degree when leading to the electrode to reduce the deformation range of lead wire when receiving external force, guarantee the stability of electrode connection coil when receiving external force, can guarantee the reliability of final device when receiving external force and act on.
In this embodiment, there is a height difference of at least 0.2mm between the surface of the groove and the cylindrical magnetic core, and this height difference means that after the winding is completed, the outgoing wire of the winding is led from the cylindrical magnetic core to the surface of the groove, and then welding is completed, and a large overhang exists. Considering that the wire diameter of the wire rod is only tens of microns, the suspension of the wire rod in this degree means that when the wire rod is subjected to a large external force or is impacted by a foreign object, the deformation which causes the winding coil to be broken can be generated, so that the inclined plane 5 needs to be arranged at the connection position of the grooves and the magnetic core of the columnar part, the deformable space of the wire rod is ensured to be small, and the reliability of the coil in the manufacturing process is improved.
As shown in fig. 3, round corners are formed on the edges of the magnetic core 3 of the column portion; the effect of the device is to ensure that the original insulating paint is not worn away or the coil is broken because the coil passes through sharp edges and corners in the process of winding the coil, so that the reliability of the electrical performance of the device is ensured.
As shown in fig. 5, four winding coils, namely a first winding w1, a second winding w2, a third winding w3 and a fourth winding w4, are wound on the magnetic core of the columnar part of the pulse transformer; the outgoing line of the first winding w1 is connected with the first groove G1 and the second groove G2, the outgoing line of the second winding w2 is connected with the third groove G3 and the fourth groove G4, the outgoing line of the third winding w3 is connected with the fifth groove G5 and the sixth groove G6, and the outgoing line of the fourth winding w4 is connected with the seventh groove G7 and the eighth groove G8.
As shown in fig. 5, when winding a coil, the coil is wound in the following manner, a first winding coil w1 and a second winding coil w2 are wound side by side, a third winding coil w3 and a fourth winding coil w4 are wound side by side, and final arrangement is completed by dividing into two layers. Therefore, the consistency of the primary coil and the secondary coil can be ensured by winding every two groups of coils side by side, and the normal electrical function of the device is ensured.
For the embodiment, the first winding w1 and the second winding w2 are led out from the second groove G2 and the third groove G3, respectively, and are wound on the magnetic core 3 of the columnar portion in a clockwise direction, and after the winding of the designed number of turns is completed, the first winding w1 and the second winding w2 are connected to the first groove G1 and the fourth groove G4, and then the third winding w3 and the fourth winding w4 are led out from the sixth groove G6 and the seventh groove G7, and the winding of the designed number of turns is completed on the magnetic core 3 of the columnar portion in a counterclockwise direction (if the winding directions of the first winding w1 and the second winding w2 are counterclockwise), and then the third winding w3 and the fourth winding w4 are connected to the fifth groove G5 and the eighth groove G8. The double-layer coil is reversely wound, so that magnetic fields induced by the two parts of coils are superposed but not offset after the upper and lower layers of coils are connected on the side of the magnetic core of the second magnetic circuit when the device is actually used, and meanwhile, the condition that the coils are wound in the same direction when the winding is started and finished is avoided. Of course, when winding the coil, the third winding w3 and the fourth winding w4 may also be wound at the lowest layer first, or the connection manner between the wound coil and the electrode is changed, and these similar design schemes are not described herein again.
As shown in fig. 2, the magnetic shield case 1 of the pulse transformer is provided with eight guide grooves, namely, a first guide groove Y1, a second guide groove Y2, a third guide groove Y3, a fourth guide groove Y4, a fifth guide groove Y5, a sixth guide groove Y6, a seventh guide groove Y7, and an eighth guide groove Y8.
The guide grooves can be divided into short guide grooves and long guide grooves according to the length of the guide grooves, the short guide grooves comprise second guide grooves Y2, third guide grooves Y3, sixth guide grooves Y6 and seventh guide grooves Y7, and the long guide grooves comprise first guide grooves Y1, fourth guide grooves Y4, fifth guide grooves Y5 and eighth guide grooves Y8. The short guide grooves are used for guiding the electrodes (P2, P3, P6 and P7) on the first magnetic circuit cores to the mounting surface, and the long guide grooves are also used for guiding the electrodes (P1, P4, P5 and P8) on the second magnetic circuit cores to the mounting surface similarly, so that the mounting difficulty of the device in the actual use process is reduced.
As shown in fig. 5, eight electrodes are distributed on the upper and lower sides of the first magnetic core and the second magnetic core, and the mounting cannot be well realized. Therefore, in the present embodiment, the coils welded in the grooves (G1, G2, G3, G4, G5, G6, G7, G8) are guided to the same side by using the electrode sheets (P1, P2, P3, P4, P5, P6, P7, P8) to facilitate the post-mounting production of the devices. As shown in fig. 2, the electrode sheets (P1, P2, P3, P4, P5, P6, P7, P8) designed in this embodiment fix the guiding grooves (Y1, Y2, Y3, Y4, Y5, Y6, Y7, Y8) on the magnetic shielding case 1, which not only facilitates automatic production, but also ensures that the electrode sheets are not short-circuited or short-circuited between different windings due to too close distance in the mounting process, thereby affecting the actual electrical performance of the device.
The invention relates to a vertical shielding type pulse transformer, which is applied to a micro-miniature pulse transformer. Because of the size limitation of the micro pulse transformer, most of the coils used in the preparation process have the wire diameter of 40-80 microns, and the smaller wire diameter and the smaller thickness of the insulating layer facilitate the mounting of welding electrodes and devices, but similarly, the wire diameter of 40-80 microns and the thinner insulating paint layer also enable the coils to be easily damaged greatly when passing sharp edges and corners in the winding process, including the situations of insulating paint damage or coil self fracture and the like, so that the coils lose original functions, the coil windings are short-circuited, the voltage resistance between the primary coil and the secondary coil is greatly reduced, and finally the electrical function of the pulse transformer is failed.
In the mounting process of the micro pulse transformer, if the traditional coated electrode is used, the welding condition of the electrode is inconvenient to observe on the welding surface of the device, the electrode is easy to desolder and rosin joint, and the welding condition of the device is inconvenient to directly test after welding. Compared with the traditional film-coated electrode, the electrode plate is partially exposed on the side surface, so that the working condition of each winding can be tested by directly using the electrode plate, a testing part is not required to be additionally arranged on a welding circuit board, and the design difficulty and the production cost are reduced. Meanwhile, the design of the electrode plate is more beneficial to subsequent mounting, and compared with the traditional coated electrode, the electrode plate can better adsorb and guide welding materials such as soldering tin and the like, so that insufficient soldering and desoldering are not easy to occur, and the reliability of the device in the actual use process can be well ensured.
When the device is working, the magnetic field induced in the winding is partially bound in the magnetic core, but for the prior micro-miniature pulse transformer, the way of complete magnetic circuit is only to adhere a cover plate with the same magnetic performance as the magnetic core body on the side far away from the electrode. Still there is more leakage flux to cause certain electromagnetic interference to external circuit and components and parts. Therefore, in the invention, the winding direction is perpendicular to the plane of the final electrode, and the magnetic cover plate for the complete magnetic circuit is improved into the magnetic shielding cover, so that the magnetic leakage of the device in a working state is ensured to be smaller, the influence of the device on surrounding devices under the working condition is reduced, meanwhile, the influence of an external electromagnetic field on the pulse transformer is also reduced, and the electrical performance of the device in normal working is ensured.
The above-mentioned contents are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical idea of the present invention falls within the protection scope of the claims of the present invention.