CN116453830A - Integrated transformer and leakage inductance adjusting method thereof - Google Patents
Integrated transformer and leakage inductance adjusting method thereof Download PDFInfo
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- CN116453830A CN116453830A CN202310246068.7A CN202310246068A CN116453830A CN 116453830 A CN116453830 A CN 116453830A CN 202310246068 A CN202310246068 A CN 202310246068A CN 116453830 A CN116453830 A CN 116453830A
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- magnetic core
- leakage inductance
- winding
- transformer
- primary winding
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- 238000000034 method Methods 0.000 title claims abstract description 23
- 238000004804 winding Methods 0.000 claims abstract description 138
- 230000005291 magnetic effect Effects 0.000 claims abstract description 89
- 125000006850 spacer group Chemical group 0.000 claims abstract description 38
- 238000004519 manufacturing process Methods 0.000 claims abstract description 24
- 230000001965 increasing effect Effects 0.000 claims abstract description 15
- 230000008569 process Effects 0.000 claims description 6
- 229910000859 α-Fe Inorganic materials 0.000 claims description 3
- 230000008878 coupling Effects 0.000 abstract description 7
- 238000010168 coupling process Methods 0.000 abstract description 7
- 238000005859 coupling reaction Methods 0.000 abstract description 7
- 239000006185 dispersion Substances 0.000 abstract description 4
- 238000012797 qualification Methods 0.000 abstract description 3
- 230000001105 regulatory effect Effects 0.000 abstract description 2
- 230000008859 change Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 230000002708 enhancing effect Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 229920002799 BoPET Polymers 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000001808 coupling effect Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
Classifications
-
- 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
- H01F27/323—Insulation between winding turns, between winding layers
-
- 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
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
- H01F27/346—Preventing or reducing leakage fields
-
- 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
- H01F41/122—Insulating between turns or between winding layers
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Coils Of Transformers For General Uses (AREA)
Abstract
The invention discloses an integrated transformer and a leakage inductance adjusting method thereof, and a magnetic core; the winding comprises a primary winding and a secondary winding, the primary winding is wound on the magnetic core, the secondary winding is wound on the outer side of the primary winding, and a spacing layer is arranged between the primary winding and the secondary winding; setting the thickness of a spacer layer according to the leakage inductance required value of the integrated transformer in the production process of the integrated transformer so as to set the distance between a primary winding and a secondary winding through the spacer layer; according to the invention, the spacer layer is additionally arranged between the primary winding and the secondary winding, so that the coupling coefficient between the primary winding and the secondary winding is increased or reduced, the leakage inductance dispersion of the transformer is effectively reduced, the manufacturing qualification rate of the transformer is improved, and when the leakage inductance of the transformer is adjusted, the winding machine is only required to be regulated to bind the turns of the insulating layer, so that production personnel can more conveniently control the leakage inductance of the transformer in the same batch, and the quality and the production efficiency of the LLC circuit are improved.
Description
Technical Field
The embodiment of the invention relates to the field of transformer production and manufacturing, but is not limited to the field of transformer production and manufacturing, in particular to an integrated transformer and a leakage inductance adjusting method thereof.
Background
The integrated transformer uses the leakage inductance of the transformer as the circuit resonance inductance, does not need special resonance inductance, has the advantages of small volume, low cost and high efficiency, is widely used all the time, and at present, the conventional process of the integrated transformer for LLC is as follows: the winding machine is used for winding materials such as winding wires, insulating tapes, retaining walls, sleeves and the like on a framework, then soldering tin is carried out, parts such as magnetic cores and the like are assembled, and dispensing impregnating paint and the like are needed, but because the winding wire tension and the winding wire density are difficult to be completely consistent in the production process, the leakage inductance of products manufactured by different persons, different equipment and even the same person by the same winding machine can be different, the data dispersion shows randomness, sometimes is biased positive and sometimes biased negative, no specific rule exists, the leakage inductance of an integrated transformer in the same batch is difficult to be located in the same interval, and the bad problems such as large leakage inductance dispersion, difficult control and the like exist under the production process of a conventional transformer, so that the LLC circuit quality is lower.
Disclosure of Invention
The following is a summary of the subject matter described in detail herein. This summary is not intended to limit the scope of the claims.
The embodiment of the invention mainly aims to provide an integrated transformer and a leakage inductance adjusting method thereof, so that the leakage inductance of the transformer can be adjusted along with the instant change of production, and the LLC circuit quality is improved.
In one aspect, an integrated transformer according to an embodiment of the present invention includes: a magnetic core; the winding comprises a primary winding and a secondary winding, the primary winding is wound on the magnetic core, the secondary winding is wound on the outer side of the primary winding, and a spacing layer is arranged between the primary winding and the secondary winding; in the process of producing the integrated transformer, the thickness of the spacer layer is set according to the leakage inductance required value of the integrated transformer so as to set the distance between the primary winding and the secondary winding through the spacer layer.
According to some embodiments of the invention, the distance between the primary winding and the secondary winding is in positive correlation with leakage inductance.
According to some embodiments of the invention, the spacer layer comprises several layers of insulating tape.
According to some embodiments of the invention, a transformer former is also provided between the primary winding and the central portion of the core.
According to some embodiments of the invention, the transformer framework comprises a first framework and a second framework, the first framework and the second framework are of an integrated structure, a first connection plane and a second connection plane which are matched with the first magnetic core and the second magnetic core are further arranged between the first framework and the second framework, the primary winding is wound on the first connection plane and the second connection plane, a first extension plane and a second extension plane are further arranged on one side, connected with the first magnetic core and the second magnetic core, of the first framework and the second framework, and through holes which are matched with the central parts of the first magnetic core and the second magnetic core are respectively arranged on the first extension plane and the second extension plane and are used for further fixing the first magnetic core and the second magnetic core.
According to some embodiments of the invention, the magnetic core comprises a first magnetic core and a second magnetic core, the first magnetic core and the second magnetic core being E-shaped magnetic cores, the first magnetic core and the second magnetic core being arranged opposite to form a central portion for winding the primary winding.
According to some embodiments of the invention, the magnetic core is a ferrite core for increasing the magnetic effect of the first and second magnetic cores.
According to some embodiments of the invention, the surface of the secondary winding is also covered with an insulating tape.
In one aspect, an embodiment of the present invention provides a leakage inductance adjustment method for an integrated transformer, where the magnetism of a primary winding, a secondary winding, and a magnetic core is unchanged, the method includes:
acquiring leakage inductance data and the leakage inductance required value of the transformer;
comparing the leakage inductance data with the leakage inductance required value to obtain a comparison result;
and determining the thickness of the spacer layer according to the comparison result so that the leakage inductance data is equal to the leakage inductance required value.
In one aspect, an embodiment of the present invention provides a method for manufacturing an integrated transformer, including:
winding the primary winding on the magnetic core;
a spacer layer is arranged on the outer side of the primary winding, and the thickness of the spacer layer is set according to the leakage inductance demand value of the transformer;
the secondary winding is wound on the outside of the spacer layer.
The beneficial effects of the invention are as follows:
through add the spacer layer between primary winding and vice side winding, increase or reduce the coupling coefficient between primary winding and the vice side winding, effectively reduce the transformer leakage inductance and discrete, improve the transformer and make the qualification rate, only need when carrying out transformer leakage inductance adjustment through adjusting the number of turns that the coiling machine wrapped the insulating layer can for the production personnel more conveniently control the leakage inductance of same batch of transformers, promote the quality and the production efficiency of LLC circuit.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
FIG. 1 is a schematic diagram of an overall structure of an adjustable leakage inductance transformer according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a magnetic core structure of an adjustable leakage inductance transformer according to an embodiment of the present invention;
FIG. 3 is a flow chart of a method for adjusting a leakage inductance adjustable transformer according to an embodiment of the present invention;
fig. 4 is a flowchart of a method for manufacturing an integrated transformer with adjustable leakage inductance according to an embodiment of the present invention.
Reference numerals:
1. a magnetic core; 11. a first magnetic core; 12. a second magnetic core; 2. a transformer skeleton; 21. a first skeleton; 22. a second skeleton; 23. a first connection plane; 24. a second connection plane; 3. a winding; 31. a primary winding; 32. a secondary winding; 4. a spacer layer; 5. an insulating tape.
Detailed Description
Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative only and are not to be construed as limiting the invention.
In the description of the present invention, it should be understood that references to orientation descriptions such as upper, lower, front, rear, left, right, etc. are based on the orientation or positional relationship shown in the drawings, are merely for convenience of description of the present invention and to simplify the description, and do not indicate or imply that the apparatus or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be construed as limiting the present invention.
In the description of the present invention, a number means one or more, a number means two or more, and greater than, less than, exceeding, etc. are understood to not include the present number, and above, below, within, etc. are understood to include the present number. The description of the first and second is for the purpose of distinguishing between technical features only and should not be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated or implicitly indicating the precedence of the technical features indicated.
In the description of the present invention, unless explicitly defined otherwise, terms such as arrangement, installation, connection, etc. should be construed broadly and the specific meaning of the terms in the present invention can be reasonably determined by a person skilled in the art in combination with the specific contents of the technical scheme.
Embodiments of the present application are further described below with reference to the accompanying drawings.
Referring to fig. 1, a magnetic core 1; the winding 3 comprises a primary winding 31 and a secondary winding 32, the primary winding 31 is wound on the magnetic core 1, the secondary winding 32 is wound on the outer side of the primary winding 31, the surface of the secondary winding 32 is covered with an insulating tape 5 for preventing electric leakage and enhancing the insulating property of the secondary winding 32, and the primary winding 31 is wound on the transformer framework 2 for gathering the magnetic field and improving the inductance efficiency; a spacer layer 4 is arranged between the primary winding 31 and the secondary winding 32; in the process of producing the integrated transformer, the thickness of the spacer layer 4 is set according to the leakage inductance required value of the integrated transformer, so that the distance between the primary winding 31 and the secondary winding 32 is set through the spacer layer 4, and the number of layers of the spacer layer 4 is increased or reduced when the automatic winding machine winds, so that the leakage inductance of the transformer is increased or reduced.
According to the integrated transformer provided by the embodiment of the invention, the spacer layer 4 is additionally arranged between the primary winding 31 and the secondary winding 32 to increase or reduce the coupling coefficient between the primary winding 31 and the secondary winding 32, so that the leakage inductance dispersion of the transformer is effectively reduced, the manufacturing qualification rate of the transformer is improved, and when the leakage inductance of the transformer is adjusted, the winding machine is only required to be regulated to wrap the turns of the insulating layer, so that production personnel can more conveniently control the leakage inductance of the transformer in the same batch, and the quality and the production efficiency of LLC circuits are improved.
Further, the material of the spacer layer 4 in this embodiment includes, but is not limited to, a rubber tape or a mylar tape, which is used to precisely adjust the relative distance between the primary winding and the secondary winding, and when the winding is performed by an automatic winding machine, four layers (including but not limited to, four layers of tape) are generally wound, so that the total thickness of the spacer layer 4 is kept at 0.4mm (including but not limited to 0.4mm, and other thicknesses are possible), and the relative distance between the primary winding 31 and the secondary winding 32 is increased, so that the thickness of the spacer layer 4 is increased, and when the winding is performed, the coupling coefficient of the primary winding 31 and the secondary winding 32 is increased or reduced to adjust the leakage inductance of the transformer to reach the required leakage inductance value for production.
It should be noted that, in the case of the number of turns of the primary winding 31 and the secondary winding 32, the winding process, and the magnetic core of the transformer, the coupling coefficient of the winding 3 is mainly determined by the separation distance between the primary winding 31 and the secondary winding 32.
Referring to fig. 2, as a further alternative embodiment, the magnetic core 1 comprises a first magnetic core 11 and a second magnetic core 12, wherein the first magnetic core 11 and the second magnetic core 12 are E-shaped magnetic cores of relatively low cost and relatively simple assembly, in this example the first magnetic core 11 and the second magnetic core 12 are butted against each other. Since the magnetic core 1 of the present embodiment adopts an E-type structure, the primary winding 31 and the secondary winding 32 are wound around the central portion where the first magnetic core 31 and the second magnetic core 32 are abutted during the winding process of the transformer, and the lead wires of the primary winding 31 and the secondary winding 32 are wound around the hanging wire portion of the transformer frame 2 to further fix the transformer structure. In order to increase the magnetic effect of the first magnetic core 11 and the second magnetic core 12, the first magnetic core 11 and the second magnetic core 12 of the embodiment adopt ferrite magnetic cores with high resistance, low eddy current loss and other advantages in a wide frequency range, so that the service performance of the integrated transformer is further improved, and the quality of an LLC circuit is improved.
Referring to fig. 1 to 2, the transformer frame 2 includes a first frame 21 and a second frame 22, the first frame 21 and the second frame 22 are in an integral structure, in order to better increase the magnetic effect between the primary winding 31 and the magnetic core 1, a first connection plane 23 and a second connection plane 24 adapted to the first magnetic core 11 and the second magnetic core 12 are added between the first frame 21 and the second frame 22 in this embodiment, the primary winding 31 is wound on the first connection plane 23 and the second connection plane 24, a first extension plane 23 and a second extension plane 24 are further disposed on a side, connected to the first magnetic core 11 and the second magnetic core 12, of the first frame 21 and the second frame 22, and in order to better fix the first magnetic core and the second magnetic core, through holes adapted to the central portions of the first magnetic core 11 and the second magnetic core 12 are disposed on the first extension plane 23 and the second extension plane 24.
It should be noted that, in the integrated transformer according to the embodiment of the present invention, the structures of the central portions of the first magnetic core 11 and the second magnetic core 12 include, but are not limited to, a cylinder and a prism, and the structure of the central portion of the magnetic core is not particularly limited in this embodiment; in addition, the structure of the spacer layer 4 provided by the embodiment of the invention is not responsible for the insulation function of the transformer, so that no matter how the number of layers of the spacer layer 4 is increased or reduced, the problems of safety regulation and performance of a transformer product cannot be caused, leakage inductance of the transformer can be adjusted along with the instant leakage inductance required value change required by production, the problems that the winding displacement tension and winding displacement density of the primary winding 31 and the secondary winding 32 are difficult to be completely consistent in the production process of the transformer, and the leakage inductance of transformers manufactured by different persons, different equipment and even the same person using the same winding machine is different are effectively solved, and the problems that the leakage inductance data of the transformer is scattered, random, and sometimes positive and sometimes negative are effectively reduced.
Referring to fig. 3, the present embodiment provides a leakage inductance adjustment method of an integrated transformer, which includes, but is not limited to, the following steps, with unchanged magnetic properties of a primary winding, a secondary winding and a magnetic core:
s101, acquiring leakage inductance data and leakage inductance required values of a transformer;
s102, comparing the leakage inductance data with the leakage inductance required value to obtain a comparison result;
s103, the leakage inductance data of the transformer is smaller than the leakage inductance required value, the number of layers of a spacer layer is increased, the relative distance between a primary winding and a secondary winding is increased, the coupling coefficient of the primary winding and the secondary winding is reduced, and the leakage inductance data of the transformer is increased;
s104, the leakage inductance data of the transformer is larger than the leakage inductance required value, the number of layers of a spacer layer is reduced, the relative distance between a primary winding and a secondary winding is reduced, the coupling coefficient of the primary winding and the secondary winding is increased, and the leakage inductance data of the transformer is reduced;
s105, adjusting the number of layers of the spacer layer according to the leakage inductance requirement of the winding, and increasing or reducing the number of layers of the insulating layer by adjusting the number of turns of the wrapping procedure of the automatic winding machine;
s106, determining the thickness of the spacer layer according to the comparison result so that the leakage inductance data is equal to the leakage inductance required value.
Referring to fig. 4, the present embodiment provides a method for manufacturing an integrated transformer, including, but not limited to, the following steps:
s201, winding the primary winding on a magnetic core;
s202, arranging a spacer layer on the outer side of a primary winding, wherein the thickness of the spacer layer is set according to the leakage inductance demand value of the transformer;
s203, winding the secondary winding on the outer side of the spacer layer.
The invention relates to an integrated transformer and a leakage inductance adjusting method thereof, which have the working principle that: the spacer layer is added between the primary winding and the secondary winding, the number of layers of the spacer layer is increased or reduced according to the leakage inductance required value of the transformer, the leakage inductance of the transformer is adjusted by enhancing or weakening the coupling effect, and the number of turns of the insulating layer is wrapped by adjusting the winding machine when the leakage inductance of the transformer is adjusted.
While the preferred embodiment of the present invention has been described in detail, the present invention is not limited to the above embodiments, and those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit and scope of the present invention, and these equivalent modifications or substitutions are included in the scope of the present invention as defined in the appended claims.
Claims (10)
1. An integrated transformer, comprising:
a magnetic core;
the winding comprises a primary winding and a secondary winding, the primary winding is wound on the magnetic core, the secondary winding is wound on the outer side of the primary winding, and a spacing layer is arranged between the primary winding and the secondary winding;
in the process of producing the integrated transformer, the thickness of the spacer layer is set according to the leakage inductance required value of the integrated transformer so as to set the distance between the primary winding and the secondary winding through the spacer layer.
2. An integrated transformer according to claim 1, wherein the distance between the primary winding and the secondary winding is in positive correlation with leakage inductance.
3. An integrated transformer according to claim 1, characterized in that the spacer layer comprises several layers of insulating tape.
4. An integrated transformer according to claim 1, wherein a transformer former is further provided between the primary winding and the central portion of the core.
5. The integrated transformer of claim 4, wherein the transformer frame comprises a first frame and a second frame, the first frame and the second frame are in an integrated structure, a first connection plane and a second connection plane adapted to the first magnetic core and the second magnetic core are further arranged between the first frame and the second frame, the primary winding is wound on the first connection plane and the second connection plane, a first extension plane and a second extension plane are further arranged on one side, connected with the first magnetic core and the second magnetic core, of the first frame and the second frame, and through holes adapted to the central parts of the first magnetic core and the second magnetic core are respectively arranged on the first extension plane and the second extension plane for further fixing the first magnetic core and the second magnetic core.
6. The integrated transformer of claim 1, wherein the magnetic core comprises a first magnetic core and a second magnetic core, the first magnetic core and the second magnetic core being E-shaped magnetic cores, the first magnetic core and the second magnetic core being disposed opposite to form a central portion for winding the primary winding.
7. The integrated transformer of claim 6, wherein the magnetic core is a ferrite core for increasing the magnetic effects of the first and second magnetic cores.
8. An integrated transformer according to claim 1, wherein the surface of the secondary winding is further covered with an insulating tape.
9. A method for adjusting leakage inductance of an integrated transformer according to any one of claims 1-8, wherein the method comprises:
acquiring leakage inductance data and the leakage inductance required value of the transformer;
comparing the leakage inductance data with the leakage inductance required value to obtain a comparison result;
and determining the thickness of the spacer layer according to the comparison result so that the leakage inductance data is equal to the leakage inductance required value.
10. A method of manufacturing an integrated transformer, for manufacturing an integrated transformer according to any one of claims 1-8, the method comprising:
winding the primary winding on the magnetic core;
a spacer layer is arranged on the outer side of the primary winding, and the thickness of the spacer layer is set according to the leakage inductance demand value of the transformer;
the secondary winding is wound on the outside of the spacer layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310246068.7A CN116453830A (en) | 2023-03-14 | 2023-03-14 | Integrated transformer and leakage inductance adjusting method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310246068.7A CN116453830A (en) | 2023-03-14 | 2023-03-14 | Integrated transformer and leakage inductance adjusting method thereof |
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| Publication Number | Publication Date |
|---|---|
| CN116453830A true CN116453830A (en) | 2023-07-18 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310246068.7A Pending CN116453830A (en) | 2023-03-14 | 2023-03-14 | Integrated transformer and leakage inductance adjusting method thereof |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117831910A (en) * | 2024-03-05 | 2024-04-05 | 珠海市睿影科技有限公司 | Planar transformer, leakage inductance adjusting method and medium |
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2023
- 2023-03-14 CN CN202310246068.7A patent/CN116453830A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117831910A (en) * | 2024-03-05 | 2024-04-05 | 珠海市睿影科技有限公司 | Planar transformer, leakage inductance adjusting method and medium |
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