CN220710093U - Coil for transformer - Google Patents

Abstract

The utility model discloses a transformer coil which is formed by winding wires in a way that the wires are in surface contact with each other and can improve the efficiency of a transformer by less winding, wherein the transformer coil is formed by winding wires, the wires with round cross sections and preset diameters are rolled up and down and left and right so that the upper surfaces and the lower surfaces of the wires are flat in the left-right direction and the left surfaces and the right surfaces of the wires are flat in the up-down direction, the wires are wound in a way that the upper surfaces and the lower surfaces and the left surfaces are in surface contact with each other, one wire positioned at the outer side is positioned between 2 wires positioned at the inner side, and the lower surfaces of the wires are in surface contact with the upper surfaces of the 2 wires positioned at the inner side.

Description

Coil for transformer

Technical Field

The utility model discloses a coil for a transformer, which is formed by winding a wire, wherein the wire with round cross section is rolled up and down and left and right and with preset diameter is formed into flat upper and lower surfaces and left and right surfaces, the wire is wound in surface contact with each other up and down and left and right, the coil space factor of the coil can be improved, and the transformer efficiency can be improved by less winding.

Background

Generally, the ratio of the sectional area of a conductor constituting a coil to the sectional area of the entire coil is called a coil space factor (coil space factor), and a conventional transformer coil is used by winding a wire having a circular cross section, and thus the wires are in line contact with each other at the time of winding, so that a large number of hollow spaces are formed between the wires, thereby reducing the transformer efficiency.

As one of the many methods for improving the efficiency of the transformer, various methods have been studied in order to improve the coil space factor (Coil Space Factor or Conductor Occupying Ratio) of the coil, and a general method for improving the coil space factor of the coil is mainly to increase the diameter of the coil or increase the number of windings.

However, in the conventional coil, a copper wire having a circular vertical cross section is generally used, and the circular cross section increases the diameter of the copper wire, so that a wasted Space (Waste Space) is generated between the coil layers to be wound, thereby reducing the coil Space factor of the coil.

In contrast, when a coil having an excessively small diameter is wound, the number of windings for the same area increases, and the resistance relatively increases, which results in a decrease in efficiency and a problem of heat generation.

Disclosure of Invention

The present utility model has been made to solve the above-mentioned problems, and an object of the present utility model is to provide a coil for a transformer, which has flat 4 upper, lower, left and right sides, is wound so that the upper, lower, left and right sides are in surface contact with each other to reduce a hollow space between the wires, so that the wires are stably wound to improve the efficiency of the transformer by less winding, the space factor of the winding coil is increased to reduce magnetic resonance, the skin effect and heat dissipation performance are improved, and resistance of the wires is reduced to reduce electric energy loss due to heat loss.

The problems to be solved by the present utility model are not limited to the above-described problems, and other problems not mentioned above will be clearly understood by those skilled in the art to which the present utility model pertains from the following description.

The coil for a transformer of the present utility model can achieve the above object.

The coil for the transformer is formed by winding wires, wherein the wires with round cross sections and preset diameters are rolled up and down and left and right so that the upper surfaces and the lower surfaces of the wires are flat in the left and right directions and the left surfaces and the right surfaces of the wires are flat in the up and down directions, the wires are wound in a manner of surface contact up and down and left and right, one wire positioned on the outer side is positioned between 2 wires positioned in the inner side, and the lower surfaces of the wires are in surface contact with the upper surfaces of the 2 wires positioned in the inner side.

Further, a curved portion is formed at a corner portion between the upper and lower surfaces and the left and right surfaces of the wire, a space portion is formed at the upper and lower surfaces of the contact portion where the left and right wires are in surface contact with each other by the curved portion, the space portion formed at the upper side of the contact portion is shielded by the lower surface of the wire wound on the outer side, and the space portion formed at the lower side of the contact portion is shielded by the upper surface of the wire wound on the inner side.

Further, the wire is flattened by the flattening assembly by flattening the upper and lower surfaces at the first time, flattening the upper and lower surfaces at the second time in the right and left direction, and flattening the left and right surfaces at the state that the upper and lower surfaces are flattened, and then flattening the upper and lower surfaces at the third time.

The rolled wire is continuously wound from the right side to the left side and the wire reaches the left end, the wire is continuously wound from the inside to the outside, and the wire is continuously wound from the left side to the right side and the wire reaches the right end, and the wire is continuously wound from the inside to the outside.

The portion of the wire wound from the inside to the outside is the left side end or the right side end of the coil longitudinal portion.

The utility model rolls the wire with round section up and down and left and right to form flat 4 faces, when the wire is wound, the wire is not only in surface contact with each other in the left and right, but also in surface contact with the wire wound on the outside and the wire measured in the inside, so the hollow space generated when the wire is wound is reduced, the efficiency of the transformer is improved by less winding, the production cost of the coil for the transformer is reduced, and the weight is also lightened.

In addition, the wires are mutually contacted in the up-down and left-right directions, so that the space factor of the winding coil is increased to reduce magnetic resonance, the skin effect and the heat dissipation performance are improved, and the resistance of the wires is reduced to reduce the energy loss caused by heat loss.

Drawings

Fig. 1 is a perspective view of a coil for a transformer according to an embodiment of the present utility model.

Fig. 2 is a cross-sectional perspective view of fig. 1.

Fig. 3 is a partial cross-sectional view of fig. 1.

Fig. 4 is a drawing of a calendaring process suitable for use with the wire of the present utility model.

Fig. 5 is a graph showing a comparison of coil duty cycle of a conventional coil having a pellet wire and a coil of the present utility model.

Symbol description

10: wire 11: curve part

20: left side 30: right side

40: upper surface 50: lower surface of

70: coil longitudinal portion a: space part

C: contact portion D: diameter of

W: space part

Detailed Description

In describing the preferred embodiment of the present utility model in detail, if it is considered that the related description of the well-known structure or function may obscure the gist of the present utility model, a detailed description thereof will be omitted.

Fig. 1 is a perspective view of a coil for a transformer according to an embodiment of the present utility model, fig. 2 is a cross-sectional perspective view of fig. 1, fig. 3 is a partial cross-sectional view of fig. 1, fig. 4 is a drawing of a wire calendaring process, and fig. 5 is a graph showing a comparison of coil duty ratio of a conventional coil having a pellet-shaped wire and a coil according to the present utility model.

As shown in fig. 1 to 3, the coil for a transformer according to the present utility model is formed by winding a wire 10, wherein the wire 10 having a circular cross section and a predetermined diameter D is rolled up and down and left and right such that an upper surface 40 and a lower surface 50 of the wire 10 are flat in a left-right direction and a left surface 20 and a right surface 30 of the wire 10 are flat in the up-down direction, the wire 10 is wound in a surface contact manner up and down and left and right, the left surface 20 and the right surface 30 are in surface contact with the left and right wires 10, and a lower surface 50 of the wire 10 positioned at an outer side and an upper surface 40 of 2 wires 10 positioned at an inner side are in surface contact.

The corners between the upper and lower surfaces 40, 50 of the wire 10 and the left and right surfaces 20, 30 are formed with curved portions 11, and hollow space portions W open at the upper and lower portions of the contact portions C between the wire 10 which are in surface contact with each other are formed, and the open upper or lower portions of the space portions W are shielded by the wire 10 wound on the outside or inside.

Further, the wire 10 is flattened by the flattening unit P by flattening the upper surface 40 and the lower surface 50 at the first time in the up and down direction, flattening the left surface 20 and the right surface 30 at the second time in the left and right direction in a state where the upper surface 40 and the lower surface 50 are flattened, and then flattening the wire at the third time in the up and down direction.

When the wire 10 having a circular cross section is rolled by the rolling members P such as rolling rolls on the upper and lower sides at the same time, the upper and lower surfaces 40 and 50 of the wire 10 become flat in the right and left directions, and the left and right surfaces 20 and 30 of the wire 10 become curved such as semicircular or circular arcs to protrude in a more circular manner.

Then, if the left and right sides of the wire 10 are rolled by the rolling assembly P in a state where the upper and lower surfaces 40 and 50 are flattened, the left and right sides 20 and 30 of the wire 10 are flattened.

When the left and right surfaces 20, 30 of the wire 10 are rolled, the rolling process is performed in a state in which the upper and lower surfaces 40, 50 of the wire 10 are supported by the rolling assembly P without moving the rolling assembly P from the upper and lower sides of the wire 10, whereby the upper and lower surfaces 40, 50 of the wire 10 are maintained in a flat state without protruding convexly when the left and right surfaces 20, 30 of the wire 10 are rolled.

That is, 4 surfaces such as the flat upper surface 40, the lower surface 50, the left surface 20, and the right surface 30 are formed on the wire 10 by rolling the wire 10 having a circular cross section up and down and left and right by the rolling assembly P.

When the wire 10 is deformed by rolling as described above, the left surface 20 of the wire 10 on the right side and the right surface 3 of the wire 10 on the left side are in surface contact with each other when the wire 10 is continuously wound from the right side to the left side so that the lower surface 50 of the wire 10 is in contact with the outer surface of a winding cylinder (not shown).

The wire 10 is wound from the right side to the left side on the outside of the winding cylinder, and when the wire 10 reaches the left end, the wire 10 is wound from the inside to the outside, and the wire 10 is laminated on the wound wire 10 and continuously wound from the left side to the right side.

That is, if the wire 10 is wound continuously from the left side to the right side after the wire 10 is wound from the inside to the outside in order to laminate the wire 10 on the wound wire 10, the right surface 30 of the wire 10 positioned on the left side and the left surface 20 of the wire 10 positioned on the right side are brought into surface contact. Further, one wire 10 located at the outer side is disposed between 2 wires 10 located at the inner side, and the lower surface 50 of the wire 10 located at the outer side and the upper surfaces 40 of the 2 wires 10 located at the inner side are in surface contact.

When the tension in winding the outer wire 10 is increased, the area of the contact surface where the lower surface 50 of the outer wire 10 and the upper surfaces 40 of the inner 2 wires 10 are in surface contact with each other is increased.

Further, the diameter D becomes larger so that the tension when winding the wire 10 located on the outer side becomes larger. When the diameter D is 1 mm, the tension is about 1 to 4.5 kgf.

The method of forming the flat 4 faces on the wire 10 having the circular cross section may include the steps of: as shown in fig. 4, a first rolling step i of providing a rolling assembly P such as a rolling roller on the upper and lower sides of the round wire 10, and pressurizing the upper and lower sides of the wire 10 with the rolling assembly P so that the upper and lower surfaces 40 and 50 of the wire 10 become flat; a second rolling step ii, after the first rolling step, setting the rolling assembly P on the left and right sides of the wire 10, and pressing the left and right sides of the wire 10 with the rolling assembly P to flatten the left and right sides 20 and 30 of the wire 10; and a third casting step iii, after which the upper surface 40 and the lower surface 50 of the wire 10 are cast again by the rolling assembly P.

Also, in the second-time pressing step ii, the upper surface 40 and the lower surface 50 of the wire 10 are continuously supported by the pressing member P before the left and right surfaces 20 and 30 of the wire 10 are pressed by the pressing member P so as to prevent the phenomenon that the upper surface 40 and the lower surface 50 of the wire 10 protrude convexly when the left and right surfaces 20 and 30 of the wire 10 are pressed.

Further, by the third step iii, the effect is achieved that the upper surface 40 and the lower surface 50 of the wire 10 protruding slightly convexly after the second step ii are rolled again by the rolling means P to be restored to a flat state or kept in a flat state.

The order of flattening the upper and lower surfaces 40, 50 and the left and right surfaces 20, 30 of the wire 10 may be as follows, the upper surface 40 and the lower surface 50 of the wire 10 may be first rolled, the left and right surfaces 20, 30 may be then rolled, the upper and lower surfaces 40, 50 of the wire 10 may be rolled after the left and right surfaces 20, 30 of the wire 10 are rolled, or the upper and lower surfaces 40, 50 and the left and right surfaces 20, 30 of the wire 10 may be simultaneously rolled.

Further, the upper and lower surfaces 20, 30 and the left and right surfaces 20, 30 of the flat hexahedral wire 10 can be formed with different heights and widths, and in particular, the left and right surfaces 20, 30 are preferably formed to have a height larger than the left and right widths of the upper and lower surfaces 40, 50, in order to prevent the phenomenon that the upper and lower heights are reduced and the wire 10 positioned outside is flatly wound due to the tension when the wire 10 is wound.

The upper and lower surfaces 40, 50 and the left and right surfaces 20, 30 are formed by curved portions 11 in the form of circular arcs at the corners of the flat wire 10. That is, 4 corners of the upper and lower surfaces 40, 50 of the lead 10, which are in contact with the left and right surfaces 20, 30, are formed with gentle curved portions 11, hollow space portions W are formed on the upper and lower sides of the contact portions C where the left and right 2 leads 10 are in surface contact, based on the curved portions 11, and the upper and lower portions of the space portions W are closed by the lead 10 wound on the outside and the inside.

That is, when the wire 10 is wound, the upper part of the space W formed above the contact portion C is shielded by the lower surface 50 of the wire 10 on the outer side, and the lower part of the space W formed below the contact portion C is shielded by the upper surface 40 of the wire 10 located inside.

Fig. 5 compares and illustrates the coil space factor S of the existing coil a having a circular cross section with the coil space factor S of the coil B of the present utility model having a flat 4-sided surface, and since the wires 10 are in surface contact with each other up and down and left and right, it can be seen that the wasted space W of the coil B of the present utility model between the wires 10 is reduced compared to the existing coil a having a circular cross section, so that the coil space factor S of the winding coil is improved by about 94% of about 10% compared to the existing coil (about 87%), thereby reducing magnetic resonance, improving skin effect and heat dissipation performance, and the resistance of the wire 10 is reduced to reduce the loss of energy caused by heat loss.

When the wire 10 is continuously wound from the left side to the right side and the wire 10 reaches the right side end, the wire 10 is wound from the inside to the outside, and the portion from the inside to the outside where the wire 10 is wound becomes the left side end or the right side end of the coil longitudinal portion 70.

As described above, when the lead wire 10 is wound in a plurality of layers around the outside of the winding cylinder and the winding cylinder is removed, the transformer coil having the square-pole space with rounded corners can be completed, and the transformer core can be inserted into the space.

Claims (5)

1. A coil for a transformer, characterized in that,

the coil for the transformer is formed by winding a wire,

the wire having a circular cross section and a predetermined diameter is rolled up and down and left and right such that the upper and lower surfaces of the wire are flat in the left and right directions and the left and right surfaces of the wire are flat in the up and down directions,

the lead wire is wound in a manner of surface contact up and down and left and right,

one wire located on the outer side is located between 2 wires of the inner side, and the lower surface is in surface contact with the upper surfaces of the 2 wires located on the inner side.

2. A coil for a transformer according to claim 1, wherein,

curved portions are formed at the corners between the upper and lower surfaces and the left and right surfaces of the wires, space portions are formed at the upper and lower surfaces of the contact portions where the left and right wires are in surface contact by the curved portions,

the space formed on the upper side of the contact portion is shielded by the lower surface of the wire wound on the outside, and the space formed on the lower side of the contact portion is shielded by the upper surface of the wire wound on the inside.

3. A coil for a transformer according to claim 1 or 2,

the wire is rolled up and down for the first time to flatten the upper and lower surfaces, and then rolled up and down for the second time to flatten the left and right surfaces in a state where the upper and lower surfaces are flattened, and then rolled up and down for the third time.

4. A coil for a transformer according to claim 1 or 2,

when the rolled wire is continuously wound from the right side to the left side and reaches the left end, the wire is wound from the inside to the outside,

the wire is wound from inside to outside when the wire is continuously wound from left to right and the wire reaches the right end.

5. A coil for a transformer according to claim 1 or 2,

the portion of the wire wound from the inside to the outside is the left side end or the right side end of the coil longitudinal portion.