CN216749552U - High-efficiency energy-saving high-power small-volume frameless transformer - Google Patents

High-efficiency energy-saving high-power small-volume frameless transformer Download PDF

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CN216749552U
CN216749552U CN202220361887.7U CN202220361887U CN216749552U CN 216749552 U CN216749552 U CN 216749552U CN 202220361887 U CN202220361887 U CN 202220361887U CN 216749552 U CN216749552 U CN 216749552U
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copper sheet
winding
magnetic core
shaped
arc
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李振华
刘国保
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Chenzhou Yuhui Electronic Technology Co ltd
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Chenzhou Yuhui Electronic Technology Co ltd
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Abstract

The utility model relates to a high-efficiency energy-saving high-power small-volume frameless transformer; the winding comprises a magnetic core component, a multi-strand enameled wire winding, a copper sheet winding, a ceramic substrate and a PCB (printed circuit board); the magnetic core assembly is formed by oppositely inserting and folding two magnetic core blocks which are symmetrical up and down, and each magnetic core block consists of a cylindrical central column, left and right arc-shaped side columns and left and right fan-shaped bottoms; the copper sheet winding is a C-shaped arc copper sheet, and a ceramic substrate is sandwiched between the upper copper sheet and the lower copper sheet to be concentrically superposed; two of the multi-strand enameled wire windings are connected in series between the pie coils, and the copper sheet windings are concentrically sandwiched up and down through the ceramic substrate. The utility model has the advantages of low loss, good heat dissipation effect, high compressive strength, uniform current distribution, safety and reliability, and can reduce the manufacturing cost.

Description

High-efficiency energy-saving high-power small-volume frameless transformer
Technical Field
The utility model relates to the technology of electronic transformers, in particular to a high-efficiency energy-saving high-power small-size frameless transformer.
Background
The high-frequency transformer in the prior art is composed of a coil, a framework and a magnetic core, wherein the coil part of the transformer is formed by sequentially winding a primary coil, a secondary coil and a feedback winding, the primary winding and the feedback winding are on the same side, and the windings are isolated and insulated by using adhesive tapes; the bobbin occupies a certain space, so that the volume of the transformer becomes large, and it is difficult to reduce the manufacturing cost. 15 of 2017, 03 and 15, chinese utility model discloses an authorization notice number CN206022065U discloses a frameless's high frequency transformer, including magnetic core assembly and winding coil, be equipped with the magnetic core axle that is horizontal setting on the magnetic core assembly, winding coil winds on it along the axial direction layer of magnetic core axle, and the magnetic core assembly bottom is fixed with the insulation board, and a plurality of lead wires that winding coil was drawn forth wear out the insulation board and form the wiring end on the insulation board. Although the framework structure is cancelled in the high-frequency transformer, the technical scheme can utilize the space of the framework, the high-frequency transformer in unit volume has higher power, and the manufacturing cost is saved. However, the transformer manufactured in this way has the problems that insulation paper is required to be wound between the magnetic core and the winding and between the windings of each layer for insulation, the manufacturing difficulty is high, the high-power full-load heat dissipation effect between the winding and the magnetic core is not ideal, the compressive strength is not high, and certain potential safety hazards exist.
SUMMERY OF THE UTILITY MODEL
Aiming at the technical problems in the prior art, the utility model provides an efficient energy-saving high-power small-volume frameless transformer which has the advantages of low loss, good heat dissipation effect, high compressive strength, uniform current distribution, safety and reliability, and can reduce the manufacturing cost.
In order to solve the problems, the utility model adopts the following technical scheme:
a high-efficiency energy-saving high-power small-volume frameless transformer consists of a magnetic core component, a plurality of strands of enameled wire windings, a copper sheet winding, a ceramic substrate and a PCB (printed circuit board);
the magnetic core component is formed by oppositely inserting and folding two magnetic core blocks which are symmetrical up and down, each magnetic core block consists of a cylindrical central column, a left arc-shaped side column, a right arc-shaped side column, and a left fan-shaped bottom part and a right fan-shaped bottom part which are respectively and integrally connected with the bottom of the left arc-shaped side column, the bottom of the cylindrical central column and the bottom of the right arc-shaped side column; the left arc-shaped side column and the right arc-shaped side column are bilaterally symmetrical, and the left sector-shaped bottom and the right sector-shaped bottom are bilaterally symmetrical;
the multi-strand enameled wire winding and the copper sheet winding are arranged on the cylindrical central column which is closed by the magnetic core component; the air gaps between the cylindrical central columns folded by the magnetic core components are filled with soft glue; the magnetic core assembly, the multi-strand enameled wire winding and the copper sheet winding are connected together by epoxy resin;
the multi-strand enameled wire winding is formed by wrapping a plurality of strands of enameled wires with Teflon self-adhesive layers, two cake-shaped coils which are mutually connected in series are overlapped between the wires through winding, and the leading-out ends of the two cake-shaped coils form the winding input end;
the copper sheet winding is formed by combining two or more copper sheets which are in a C-shaped arc shape and have the thickness of 0.5-1.5 mm; the inner diameter of the circular arc-shaped part of the copper sheet is matched with the outer diameter of the cylindrical central column of the magnetic core assembly, and the end part of the circular arc of the copper sheet is designed into an asymmetric central pin and an asymmetric edge pin; the central pin is a pin with one end part led out along the arc radial direction of the copper sheet, the edge pin is a pin led out from the other end part, and the edge pin deviates from the central pin in parallel; the central pin and the edge pin of each copper sheet of the copper sheet winding are connected with the PCB together, and the copper sheets are connected in parallel or in series through copper-clad circuits of the PCB to form a winding output end;
the ceramic substrate is a ceramic sheet which is formed by combining an annular part and a rectangular part into an omega shape and has the thickness of 0.1-0.5mm, the inner diameter of the annular part of the ceramic substrate is matched with the outer diameter of the cylindrical central column of the magnetic core component, and the outer diameter of the annular part of the ceramic substrate is equal to the outer diameter of the arc-shaped part of the copper sheet winding copper sheet; the rectangular part of the ceramic substrate is externally connected with a heat dissipation end;
the copper sheet combination is that a ceramic substrate is sandwiched between an upper copper sheet and a lower copper sheet to be concentrically superposed; the front sides and the back sides of the upper copper sheet and the lower copper sheet are opposite, so that the side pin of one layer of copper sheet is positioned on the left side of the central pin, and the side pin of the other layer of copper sheet is positioned on the right side of the central pin, and the copper sheets are alternately overlapped;
two of the stranded enameled wire windings are connected in series between the pie-shaped coils, and the copper sheet windings are sandwiched and overlapped in an upper and a lower concentric mode; a ceramic substrate is clamped between the copper sheet on the uppermost layer of the copper sheet winding and the pie coils of the multi-strand enameled wire winding, and a ceramic substrate is also clamped between the copper sheet on the lowermost layer of the copper sheet winding and the pie coils of the multi-strand enameled wire winding.
Compared with the prior art, the magnetic core block is a magnetic core body material of manganese-nickel-zinc ferrite, has the excellent performances of high frequency, high saturation, high resistivity, high magnetic flux density and low magnetic loss, has no obvious change with temperature rise and loss at 80 ℃ and above 120 ℃ and at 25 ℃, and is particularly suitable for being used as a frameless transformer with high power and small volume; the shape and the structure of the transformer lead the temperature rise of the transformer to be stable, the volume to be small and the assembly operation of frameless operation to be convenient. The input end of the transformer adopts a high-strength multi-strand enameled wire wrapped by a Teflon self-adhesive layer, and the working current is high. The output end of the transformer uses the C-shaped arc copper sheet as the winding, the laminated part is isolated by the ceramic substrate made of high-temperature insulating material, and the ceramic substrates arranged between the windings of the transformer, between the copper sheets and between the input and the output can facilitate the heat generated by the copper sheets of the secondary winding to be conducted to the ceramic substrate, so that the heat dissipation performance is greatly improved.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
FIG. 1 is a schematic partial cross-sectional view of the present invention.
Fig. 2 is an electrical schematic of fig. 1.
FIG. 3 is a schematic view of a magnetic core assembly of the present invention.
FIG. 4 is a schematic view of a ceramic substrate according to the present invention.
Fig. 5 is a schematic diagram of the copper sheet winding of the utility model.
Fig. 6 is a schematic view of a structure in which two pancake coils of a multi-strand enameled wire winding according to the present invention are connected in series with each other.
FIG. 7 is a schematic diagram of a PCB structure according to the present invention.
The reference numbers are: 1 a magnetic core assembly; 2, winding a plurality of strands of enameled wires; 3, winding of copper sheets; 4 a ceramic substrate; 5, a PCB board; 6, magnetic core block; 7 a cylindrical central column; 8 left arc side column; 9 right arc-shaped side column; 10 left sector bottom; 11 right sector bottom; 12 a teflon self-adhesive layer; 13 a pancake coil; 14 winding input ends; 15 circular arc-shaped part of copper sheet; 16 central pins; 17 side pins; 18 a ceramic substrate annular portion; 19 rectangular portion of ceramic substrate.
Detailed Description
The utility model is further described with reference to the following figures and examples.
Referring to fig. 1-7, a high-efficiency energy-saving high-power small-volume frameless transformer comprises a magnetic core assembly 1, a multi-strand enameled wire winding 2, a copper sheet winding 3, a ceramic substrate 4 and a PCB board 5;
the magnetic core component 1 is formed by oppositely inserting and folding two magnetic core blocks 6 which are symmetrical up and down, and each magnetic core block 6 is composed of a cylindrical central column 7, a left arc-shaped side column 8, a right arc-shaped side column 9, and a left fan-shaped bottom 10 and a right fan-shaped bottom 11 which are respectively and integrally connected with the bottom of the left arc-shaped side column 8, the bottom of the cylindrical central column 7 and the bottom of the right arc-shaped side column 9; the left arc-shaped side column 8 and the right arc-shaped side column 9 are bilaterally symmetrical, and the left fan-shaped bottom 10 and the right fan-shaped bottom 11 are bilaterally symmetrical;
the multi-strand enameled wire winding 2 and the copper sheet winding 3 are arranged on a cylindrical central column 7 closed by the magnetic core component 1; the magnetic core assembly 1 is folded to form an air gap on the cylindrical central column 7, and the air gap is filled with soft glue; the magnetic core component 1, the multi-strand enameled wire winding 2 and the copper sheet winding 3 are connected together by epoxy resin;
the multi-strand enameled wire winding 2 is formed by wrapping a plurality of strands of enameled wires with Teflon self-adhesive layers 12, two pie coils 13 which are mutually connected in series are stacked between the wires through winding, and the leading-out ends of the two pie coils 13 form a winding input end 14;
the copper sheet winding 3 is formed by combining two or more copper sheets which are in a C-shaped arc shape and have the thickness of 0.5-1.5 mm; the inner diameter of the circular arc-shaped part 15 of the copper sheet is matched with the outer diameter of the cylindrical central column 7 of the magnetic core component 1, and the ends of the circular arc of the copper sheet are designed into an asymmetrical central pin 16 and an asymmetrical edge pin 17; the central pin 16 is a pin with one end part led out along the radial direction of the copper sheet arc, the side pin 17 is a pin led out from the other end part, and the side pin 17 is deviated from the central pin 16 in parallel; the central pin 16 and the edge pin 17 of each copper sheet of the copper sheet winding 3 are connected with the PCB 5 together, and the copper sheets are connected in parallel or in series through a copper-clad circuit of the PCB 5 to form a winding output end;
the ceramic substrate 4 is a ceramic sheet which is formed by combining an annular part 18 and a rectangular part 19 into an omega shape and has the thickness of 0.1-0.5mm, the inner diameter of the annular part 18 of the ceramic substrate 4 is matched with the outer diameter of the cylindrical center post 7 of the magnetic core component 1, and the outer diameter is equal to the outer diameter of the circular arc-shaped part 15 of the copper sheet winding 3; the rectangular portion 19 of the ceramic substrate 4 is externally connected with a heat dissipation end;
the copper sheet combination is that a ceramic substrate 4 is sandwiched between an upper copper sheet and a lower copper sheet and is superposed concentrically; the front and back sides of the upper copper sheet and the lower copper sheet are opposite, so that the side pin 17 of one layer of copper sheet is positioned on the left side of the central pin 16, and the side pin 17 of the other layer of copper sheet is positioned on the right side of the central pin 16, and the copper sheets are alternately stacked;
two of the multi-strand enameled wire windings 2 are connected in series between pie-shaped coils 13, and the copper sheet windings 3 are sandwiched and overlapped in an upper and a lower concentric mode; wherein, a layer of ceramic substrate 4 is clamped between the copper sheet on the uppermost layer of the copper sheet winding 3 and the pie-shaped coils 13 of the multi-strand enameled wire winding 2, and similarly, a layer of ceramic substrate 4 is also clamped between the copper sheet on the lowermost layer of the copper sheet winding 3 and the pie-shaped coils 13 of the multi-strand enameled wire winding 2.
The magnetic core blocks 6 of the magnetic core assembly 1 are sintered soft magnetic ferrites composed of a mixture of ferric ions as the main cation and other oxides.
Furthermore, the sectional area of the left arc-shaped side column 8 of the magnetic core block 6 and the sectional area of the right arc-shaped side column 9 of the magnetic core block 6 are both 0.8 times larger than that of the cylindrical central column 7.
The utility model has the beneficial effects that:
the magnetic core block 6 is a magnetic core body material of manganese-nickel-zinc ferrite, has high resistivity, excellent performances of high frequency, high saturation magnetic flux density and low magnetic loss, has no obvious change of temperature rise and loss at the temperature of 80 ℃ and above 120 ℃ and 25 ℃, and is particularly suitable for being used as a frameless transformer with high power and small volume; the shape and the structure of the transformer lead the temperature rise of the transformer to be stable, the volume to be small and the assembly operation of frameless operation to be convenient; the sectional areas of the left arc-shaped side column 8 and the right arc-shaped side column 9 of the magnetic core block 6 are respectively 0.8 times larger than that of the cylindrical central column 7; a magnetic flux loop is formed by the cylindrical central column 7 of the magnetic core block 6, the left and right arc-shaped side columns 9 and the left and right fan-shaped bottoms 11, the effective sectional area of a magnetic circuit is increased, and magnetic leakage and leakage inductance are reduced. Compared with the prior art in the same high-frequency state, the transformer has the advantages that the loss is lower than that of a conventional transformer, the power which can be borne by the transformer is high, the forming is convenient, and the mass production is facilitated;
secondly, the input end 14 of the transformer adopts a high-strength multi-strand enameled wire wrapped by the Teflon self-adhesive layer 12, and the skin effect of the transformer is greatly reduced when working current passes through a conductor compared with the case that a single-strand enameled wire is adopted to work in a high-frequency state; the working current is large, the magnetic field generated by the current is relatively uniform, and the utilization rate is greatly increased. But the high-voltage resistance effect of the multi-strand enameled wire is very poor, and the winding is difficult; therefore, the utility model wraps the wires together by using the adhesive Teflon during the winding process, thereby achieving the effects of convenient manufacture, strong high pressure resistance and convenient batch production;
the output end of the transformer is provided with the C-shaped arc copper sheets as windings, the laminated part is isolated by the ceramic substrate 4 made of high-temperature insulating materials, and the C-shaped arc copper sheets are connected in parallel by materials with low resistivity, so that the heat dissipation effect is good and the loss is low; the winding structure of the utility model has the guarantee no matter the high current is, the low voltage is fully loaded and output;
the ceramic substrate 4 between the transformer windings, the copper sheets and the copper sheets, and between the input and the output can facilitate the heat generated by the copper sheets of the secondary winding to be conducted to the ceramic substrate 4; the rectangular part 19 of the ceramic substrate 4 can be effectively and conveniently connected with the air-cooled aluminum alloy fin;
the transformer directly assembles a plurality of strands of enameled wire windings 2 and copper sheet windings 3 on a magnetic core assembly 1, wherein air gaps between cylindrical central columns 7 folded by the magnetic core assembly 1 are filled with soft glue; the magnetic core assembly 1, the multi-strand enameled wire winding 2 and the copper sheet winding 3 are connected together by epoxy resin, so that the vibration noise caused by high frequency or vibration loops in a power panel is greatly reduced. There is the space between winding and the magnetic core, also has the great promotion of the big heat dispersion of space heat dispersion between the winding.

Claims (2)

1. A high-efficiency energy-saving high-power small-volume frameless transformer consists of a magnetic core component (1), a plurality of strands of enameled wire windings (2), a copper sheet winding (3), a ceramic substrate (4) and a PCB (printed circuit board) (5); the method is characterized in that:
the magnetic core component (1) is formed by oppositely inserting and folding two magnetic core blocks (6) which are symmetrical up and down, and each magnetic core block (6) is composed of a cylindrical central column (7), a left arc-shaped side column (8), a right arc-shaped side column (9), and a left fan-shaped bottom (10) and a right fan-shaped bottom (11) which are integrally connected with the bottom of the left arc-shaped side column (8), the bottom of the cylindrical central column (7) and the bottom of the right arc-shaped side column (9) respectively; the left arc-shaped side column (8) and the right arc-shaped side column (9) are bilaterally symmetrical, and the left fan-shaped bottom (10) and the right fan-shaped bottom (11) are bilaterally symmetrical; the multi-strand enameled wire winding (2) and the copper sheet winding (3) are arranged on a cylindrical central column (7) closed by the magnetic core component (1); the magnetic core assembly (1) is folded in the air gap formed on the cylindrical central column (7) and filled with soft glue; the magnetic core assembly (1), the multi-strand enameled wire winding (2) and the copper sheet winding (3) are connected together by epoxy resin;
the multi-strand enameled wire winding (2) is formed by wrapping a multi-strand enameled wire with a Teflon self-adhesive layer (12), two cake-shaped coils (13) which are connected in series are overlapped between the wires through winding, and the leading-out ends of the two cake-shaped coils (13) form a winding input end (14);
the copper sheet winding (3) is formed by combining two or more copper sheets which are in a C-shaped arc shape and have the thickness of 0.5-1.5 mm; the inner diameter of the circular arc-shaped part (15) of the copper sheet is matched with the outer diameter of the cylindrical central column (7) of the magnetic core assembly (1), and the end part of the circular arc of the copper sheet is designed into an asymmetrical central pin (16) and an asymmetrical edge pin (17); the central pin (16) is a pin with one end part led out along the radial direction of the copper sheet arc, the side pin (17) is a pin led out from the other end part, and the side pin (17) deviates from the central pin (16) in parallel; the central pin (16) and the side pin (17) of each copper sheet of the copper sheet winding (3) are connected with the PCB (5) together, and the copper sheets are connected in parallel or in series through a copper-clad circuit of the PCB (5) to form a winding output end;
the ceramic substrate (4) is a ceramic sheet which is formed by combining an annular part (18) and a rectangular part (19) into an omega shape and has the thickness of 0.1-0.5mm, the inner diameter of the annular part (18) of the ceramic substrate (4) is matched with the outer diameter of the cylindrical central column (7) of the magnetic core component (1), and the outer diameter is equal to the outer diameter of the arc-shaped part (15) of the copper sheet winding (3); the rectangular part (19) of the ceramic substrate (4) is externally connected with a heat dissipation end;
the copper sheet combination is characterized in that a ceramic substrate (4) is sandwiched between an upper copper sheet and a lower copper sheet and is superposed concentrically; the front and back sides of the upper copper sheet and the lower copper sheet are opposite, so that the side pins (17) of one layer of copper sheet are positioned on the left side of the central pin (16), and the side pins (17) of the other layer of copper sheet are positioned on the right side of the central pin (16), and are alternately overlapped;
the copper sheet winding (3) is sandwiched and overlapped between two pie-shaped coils (13) of the multi-strand enameled wire winding (2) which are connected in series with each other in an upper and lower concentric manner; a ceramic substrate (4) is clamped between the copper sheet on the uppermost layer of the copper sheet winding (3) and the pie-shaped coils (13) of the multi-strand enameled wire winding (2), and similarly, a ceramic substrate (4) is also clamped between the copper sheet on the lowermost layer of the copper sheet winding (3) and the pie-shaped coils (13) of the multi-strand enameled wire winding (2).
2. The high-efficiency energy-saving high-power small-volume frameless transformer of claim 1, wherein: the sectional areas of the left arc-shaped side column (8) and the right arc-shaped side column (9) of the magnetic core block (6) are respectively 0.8 times larger than that of the cylindrical central column (7).
CN202220361887.7U 2022-02-23 2022-02-23 High-efficiency energy-saving high-power small-volume frameless transformer Active CN216749552U (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202220361887.7U CN216749552U (en) 2022-02-23 2022-02-23 High-efficiency energy-saving high-power small-volume frameless transformer

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202220361887.7U CN216749552U (en) 2022-02-23 2022-02-23 High-efficiency energy-saving high-power small-volume frameless transformer

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Publication Number Publication Date
CN216749552U true CN216749552U (en) 2022-06-14

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Country Status (1)

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