KR20220060527A - Transformer, packaging and manufacturing method thereof, and wattmeter thereof - Google Patents

Abstract

The present invention discloses a transformer, a method for packaging and manufacturing the transformer, and a wattmeter. The transformer includes a transformer housing, an annular magnetic core housed within the transformer housing, and a secondary current wire housed within the transformer housing and wound on the annular magnetic core. The annular magnetic core includes a magnetic core housing and an ultrafine crystal magnetic core within the magnetic core housing. The transformer housing includes a rigid material portion and a flexible material portion which are integrally arranged. The rigid material portion and the soft material portion jointly form an annular receiving cavity having a closed bottom. The outer sidewall is part of the rigid material portion. The inner sidewall is part of the soft material portion. A through hole is formed on the inner side of the inner sidewall for the primary current wire to pass therethrough. The inner sidewall protrudes into the through hole to resist soft interference portions interfering with the primary current wire. The soft material portion is a high temperature resistant material. The annular receiving cavity is filled with a packaging material. In this way, the functions of anti-vibration and anti-leakage of the ultrafine crystal magnetic core transformer can be realized.

Description

Transformer, packaging and manufacturing method thereof, and wattmeter thereof

FIELD OF THE INVENTION The present invention relates to the technical field of transformers, and in particular to a transformer for measuring a wattmeter, a method for packaging and manufacturing the transformer, and a wattmeter having the transformer.

A transformer is a device used, metered, or measured to isolate electrical parameters. Transformers are particularly suitable for electronic wattmeters. Small current (voltage) transformer products cover almost all aspects in the application of the overall power system.

Transformers generally include a magnetic core on which a secondary current wire coil is wound. At present, among the power transformers widely used in the power field, they have very strict requirements on magnetic core materials. Not only are high magnetic indicators required (eg, high permeability, high saturation magnetic inductance, low loss, etc.), but also magnetic core materials are needed. The overall magnetization curve meets certain conditions to ensure the accuracy of the transformer over the entire measuring range. In recent years, the application of amorphous microcrystalline alloys as transformer cores has gradually attracted the attention of those skilled in the art.

Amorphous refers to when the solidification rate of a metal or alloy is very fast (eg, when an iron-boron alloy melt solidifies at a cooling rate of up to 1 million degrees/second). Atoms are frozen before being neatly arranged. The final arrangement of atoms resembles liquid and chaotic states, which are amorphous alloys. Compared with traditional metallic magnetic materials, amorphous alloys have disordered arrangement of atoms, amorphous anisotropy, and high resistivity, so they have high magnetic permeability and low loss. The magnetic properties of amorphous alloys are by far the most important field of practical application of amorphous alloys. Besides, the amorphous processing technique is easy to handle. Compared to other magnetic materials, amorphous alloys have a wide range of chemical compositions. Moreover, even the same material can easily obtain the necessary magnetic properties through different subsequent treatments. Accordingly, the magnetic properties of amorphous alloys are very tractable, and there are many choices, which provide convenience for the selection of power electronic components. On the other hand, the amorphous manufacturing process is energy-saving and environmentally friendly. Because of the traditional thin sheet steel, several process links and dozens of procedures are required, from steelmaking, casting, ingot blooming, blooming, annealing, hot rolling, annealing, pickling, finishing rolling, shearing to finished sheeting. Because of the many links and complex processes, traditional steel companies are large energy consuming polluting companies, known as "water tigers" and "electric tigers". The production of amorphous alloy is sprayed directly after steelmaking, and the finished thin strip is manufactured in one step. The process is greatly simplified, a lot of valuable energy is saved, and no pollutants are emitted, which is very beneficial for environmental protection. It is precisely because the amorphous alloy manufacturing process is energy-saving, and its magnetic properties are excellent, which reduces losses during use of related instrument applications, so it is called the green material and the material of the 21st century.

However, due to the structural relaxation of the amorphous strip during heat treatment, brittleness occurs and the toughness is poor. When subjected to an external force, it is brittle and the soft magnetic properties will decrease accordingly, so there are certain limitations in the application of this material.

In consideration of this, it is necessary to design a transformer having a better magnetic index and better stability in use to overcome the above technical problems.

In order to solve the above technical problems, it is an object of the present invention to provide a transformer having a better magnetic index and better stability in use, a method for packaging and manufacturing the transformer, and a wattmeter having the transformer.

In order to achieve the above object, the present invention adopts the following technical solutions:

A transformer used for sleeve on a primary current wire, the transformer comprising a transformer housing, an annular magnetic core housed within the transformer housing, and a secondary current wire housed within the transformer housing and wound on the annular magnetic core. . The annular magnetic core includes an ultrafine crystal magnetic core. The transformer housing includes a rigid material portion and a flexible material portion integrally arranged. The rigid material portion and the flexible material portion jointly define an annular receiving cavity having a closed bottom. The annular receiving cavity includes an annular bottom wall, an outer sidewall surrounding a perimeter of the annular bottom wall, and an inner sidewall surrounding a middle of the annular bottom wall. The annular magnetic core is proximal to the annular bottom wall, is sleeved on an outer side of the inner sidewall, and is received within the inner side of the outer sidewall. The outer sidewall is a portion of the rigid material portion and the inner sidewall is a portion of the flexible material portion. The inner side of the inner sidewall defines a through hole for the primary current wire to pass through. The inner sidewall is provided with a soft interference portion that protrudes into the through hole and is used to resist and impede the primary current wire. The soft material portion is a high temperature resistant material, and the annular receiving cavity is filled with a packaging material for holding the annular magnetic core.

As a further refinement of the present invention, the ultrafine crystal magnetic core is made of a thin strip of amorphous material that is wound around one turn and then heat treated.

As a further refinement of the present invention, the amorphous material is formed by solidifying an alloy melt comprising ferromagnetic elements and vitrifying elements at a cooling rate of 1 million degrees/second.

As a further refinement of the present invention, the ferromagnetic elements comprise iron, cobalt, nickel, and/or any combination thereof; The vitrifying elements include silicon, boron, carbon, and/or any combination thereof.

As a further improvement of the present invention, the annular magnetic core includes a magnetic core casing in which the ultrafine crystal magnetic core is accommodated, and the magnetic core casing is in the shape of a circular ring wrapped around the outside of the ultrafine crystal magnetic core. am.

As a further development of the present invention, the ultrafine crystal magnetic core is immersed and hardened in the annular receiving cavity.

As a further development of the invention, the rigid material portion comprises an annular bottom end wall extending along a direction from the outer sidewall to the through hole. The annular bottom end wall is provided with an intermediate hole corresponding to the through hole and through which the primary current wire is used. The flexible material portion includes an annular bottom plate extending along a direction from the inner sidewall to the outer sidewall. The bottom end wall and the bottom plate are integrally arranged with each other to form the annular bottom wall.

As a further refinement of the invention, the bottom end wall is provided with a plurality of small cylinders distributed around the outer side of the intermediate hole. The annular bottom plate is provided with a plurality of apertures distributed around the outer side of the inner sidewall, the small cylinders extending through and secured to the apertures.

As a further refinement of the present invention, the top of each small cylinder extends integrally with a cap covering the bottom plate to prevent the bottom plate from being separated from the small cylinders.

As a further development of the invention, the annular bottom plate is insert molded into the bottom end wall.

As a further development of the invention, the annular bottom plate is provided with holes distributed on the outer side of the inner side wall, the holes being embedded in the bottom wall.

In order to achieve the above object, the present invention also adopts the following technical solutions:

A power meter comprising a power meter casing, a metering device, a metering display device, and a connection structure of a transformer and a wiring terminal, wherein the metering device, the metering display device and the connection structure of the transformer and the wiring terminal are located in the power meter casing. A connection structure between the transformer and the wiring terminal includes the above-described transformer, a primary current wire passing through the transformer, and a wiring terminal electrically connected to the primary current wire.

As a further improvement of the present invention, the wiring terminal includes a main body and a columnar body extending forwardly from the main body. The columnar body defines a connection hole recessed from the columnar body in the front-rear direction. The main body is provided with a wiring hole recessed from the main body in the front-rear direction. The connection hole and the wiring hole face each other along the front-rear direction and do not communicate with each other. The primary current wire passes through the connection hole.

In order to achieve the above object, the present invention also adopts the following solution:

A method for packaging and manufacturing a transformer as described above, the method for packaging and manufacturing the transformer comprising:

manufacturing an annular magnetic core on which a secondary current wire coil is wound, wherein the annular magnetic core includes the ultrafine crystal magnetic core;

manufacturing the transformer housing, the transformer housing comprising a rigid material portion and a flexible material portion integrally arranged, wherein the rigid material portion and the flexible material portion jointly form an annular receiving cavity having a closed bottom wherein the annular receiving cavity comprises an annular bottom wall, an outer sidewall surrounding a perimeter of the annular bottom wall, and an inner sidewall surrounding a middle of the annular bottom wall, the outer sidewall being part of the rigid material portion , wherein the inner sidewall is part of the flexible material portion, the inner side of the inner sidewall defines a through hole for the primary current wire to pass through, the inner sidewall projecting into the through hole and resisting the primary current wire and a soft interference portion used to impede the wire is provided, the flexible material portion being a high temperature resistant material;

assembling the annular magnetic core on which the secondary current wire coil is wound into the annular receiving cavity; and

injecting the packaging material into the annular receiving cavity to complete the packaging;

includes

In order to achieve the above object, the present invention adopts the following technical solution: A method for packaging and manufacturing the above-described transformer, the method for packaging and assembling the transformer:

manufacturing an annular magnetic core on which the rigid material portion, the flexible material portion and the secondary current wire coil are wound, respectively; The annular magnetic core comprises the ultrafine crystal magnetic core, and the rigid material portion comprises a lower end wall having an intermediate aperture and an outer side wall surrounding an outer side of the lower end wall, the lower end wall including the A plurality of small cylinders are provided distributed around an outer side of the intermediate hole, the flexible material portion comprising an inner sidewall of a cylindrical hollow configuration and an annular bottom plate extending outwardly from the inner sidewall, the through hole including the primary formed on an inner side of the inner sidewall for a current wire to pass therethrough, the inner sidewall being provided with a soft interference portion protruding into the through hole and used to resist and impede the primary current wire; wherein the soft material portion is a high temperature resistant material, the annular bottom plate being perforated with holes distributed around the outer side of the inner sidewall;

firmly attaching the annular bottom plate to the bottom end wall and allowing the small cylinders to extend through and secured to the apertures to form an annular receiving cavity having a sealed bottom;

assembling the annular magnetic core on which the secondary current wire coil is wound into the annular receiving cavity; and

injecting the packaging material into the annular receiving cavity to complete the packaging;

includes

As a further refinement of the present invention, after allowing the small cylinders to extend through and secured to the bores, the method for packaging and manufacturing the transformer comprises a flat shape integrally extending on top of each small cylinder. The method further comprises ultrasonically riveting the small cylinders to provide a cap, the small cylinders passing through the holes and then riveting to the bottom plate.

In order to achieve the above object, the present invention also adopts the following technical solutions:

A method for packaging and manufacturing a transformer as described above, comprising:

manufacturing an annular magnetic core on which a secondary current wire coil is wound, the annular magnetic core comprising an ultrafine crystal magnetic core;

simultaneously forming the transformer housing from two different flexible and rigid materials by using a two-color plastic injection machine, the transformer housing comprising the rigid material part and the flexible material part, the flexible material part being cylindrical hollow an inner sidewall of construction and an annular bottom plate extending outwardly from the inner sidewall, wherein the through hole is formed on the inner side of the inner sidewall for the primary current wire to pass therethrough, the inner sidewall includes the through hole a soft interference portion protruding into and used to resist and impede the primary current wire, the soft material portion is a high temperature resistant material, the rigid material portion includes a bottom end wall having an intermediate hole and the bottom and an outer sidewall surrounding the end wall, wherein the bottom plate is formed by injection molding such that the inner sidewall, the outer sidewall, the bottom plate and the bottom end wall form an annular receiving cavity having a sealed bottom. being built into the wall;

assembling the annular magnetic core on which the secondary current wire coil is wound into the annular receiving cavity; and

injecting the packaging material into the annular receiving cavity to complete the packaging;

includes

As a further refinement of the present invention, the simultaneous forming of the transformer housing from two different flexible and rigid materials by using the two-color plastic injection machine comprises first injection molding the flexible material part, and then the flexible material part. placing the material portion into a mold to eject the rigid material portion outward; In this way, the annular bottom plate of the flexible material part is embedded in the rigid material part.

As a further refinement of the present invention, the simultaneous forming of the transformer housing from two different soft and rigid materials by using the two-color plastic injection machine gives preference to the outer sidewall of the rigid material part and the part of the bottom end wall. injection molding; then, the flexible material portion is formed on a portion of the bottom end wall; Then, another part of the bottom end wall is further injection molded on the outside of the annular bottom plate of the flexible material part; In this way, the annular bottom plate of the flexible material part is embedded in the rigid material part.

As a further development of the present invention, the annular bottom plate of the flexible material part is provided with a plurality of holes distributed at intervals during molding, the holes allowing the rigid material part to pass through during injection molding.

Compared with the prior art, the annular magnetic core of the present invention includes a magnetic core casing and an ultrafine crystal magnetic core accommodated in the magnetic core casing. The transformer housing includes a rigid material portion and a flexible material portion which are integrally arranged. The rigid material portion and the soft material portion jointly form an annular receiving cavity having a closed bottom. The soft material portion is provided with a soft interference portion to resist and disrupt the primary current wire. The soft material portion is a high temperature resistant material. The annular receiving cavity is filled with a packaging material for holding the annular magnetic core. Such a setting can realize the functions of anti-vibration and anti-leakage of the ultrafine crystal magnetic core transformer.

1 is a schematic perspective view of a connection structure of a transformer and a wiring terminal according to an embodiment of the present invention.
2 is a schematic perspective view of the structure of the transformer of the present invention.
3 is a partial exploded view of the structure of the transformer of the present invention.
4 is a schematic exploded view of a rigid material portion and a flexible material portion in the first and third embodiments of the present invention;
Fig. 5 is a schematic diagram of the structures of a rigid material part and a soft material part after ultrasonic riveting in the first embodiment of the present invention;
Fig. 6 is a front view of the rigid material part and the flexible material part after ultrasonic riveting in the first embodiment of the present invention;
7 is a side cross-sectional view of a rigid material portion and a soft material portion after ultrasonic riveting in the first embodiment of the present invention;
8 is a schematic diagram of the structure of a flexible material part of a second embodiment of the present invention;
9 is a schematic perspective view of a rigid material portion and a flexible material portion after integral injection molding according to a second embodiment of the present invention;
Fig. 10 is a side cross-sectional view of a rigid material portion and a flexible material portion after integral injection molding according to a second embodiment of the present invention;
11 is a side cross-sectional view before the rigid material part and the flexible material part are inserted and secured according to a third embodiment of the present invention;
12 is a side cross-sectional view after the rigid material part and the flexible material part are inserted and secured according to a third embodiment of the present invention;
Fig. 13 is a schematic perspective view after the rigid material part and the flexible material part are inserted and fixed according to the third embodiment of the present invention;
14 is a schematic exploded view of the internal magnetic core of the transformer of the present invention;
15 is a schematic diagram of a framework of a power meter of the present invention;
Reference number:
Connection structure of transformer and wiring terminals: 100
Transformer: 1 Transformer housing: 10
Annular receiving cavity: 101 Annular bottom wall: 102
Bottom: 103 Packaging Material: 104
Rigid material part: 11 Bottom end wall: 111
Outer sidewall: 112 Middle hole: 113
Small Cylinder: 114 Cap: 115
Soft material part: 12 Bottom plate: 121
Inner sidewall: 122 Through hole: 123
Soft interference part: 124 Hole: 125
Magnetic Core: 13 Magnetic Core Housing: 132
Ultrafine crystal magnetic core: 133 Secondary current wire: 14
Lead Wire: 15 Primary Current Wire: 2
Wiring terminals: 3 Body: 31
Wiring hole: 311 Columnar body: 32
Connection hole: 321 Wattmeter: 4
Power meter casing: 41 Metering device: 42
Weighing display unit: 43 Wiring terminal box: 44

Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that, unless specifically indicated otherwise, the relative arrangement of components and steps, numerical expressions, and numerical values presented in these examples do not limit the scope of the present invention.

The following description of at least one exemplary embodiment is merely exemplary in nature and in no way serves as any limitation on the invention and its application or use.

Techniques and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the techniques and equipment should be considered part of the specification.

In all examples shown and discussed herein, any particular value should be construed as illustrative only and not restrictive. Accordingly, other examples of the illustrative embodiment may have different values.

It should be noted that if a particular item is defined in one drawing, it need not be further discussed in subsequent drawings, as like reference numbers and characters indicate like items in the drawings that follow.

In the field of transformer applications, as a supplier familiar with the market demand of the industry, Weida Electronic Co., Ltd is fully aware of the problems in the existing technology. His R&D team invested more based on its own original technology, conducted long-term and large-scale experiments, program screening, and large-scale customer surveys, and finally obtained the technical solution of the present invention.

1 to 13 , a transformer 1 is used to be sleeved on a primary current wire 2 . In this way, the transformer 1 can be used to isolate and detect power data on the primary current wire 2 . The transformer 1 includes a transformer housing 10 , an annular magnetic core 13 housed in the transformer housing 10 , and a secondary current wire 14 housed in the transformer housing 10 and wound on the annular magnetic core 13 . includes In the present invention, each term "annular" does not specifically refer to a circular ring, but any shape having a hole in the middle for the primary current wire 2 to pass through is included in the scope of the term "annular". Moreover, the inner and outer circumferences of the term “annular” are not limited to a circular shape, but may have any shape. The annular magnetic core 13 includes a magnetic core housing 132 and an ultrafine crystal magnetic core 133 housed in the magnetic core housing 132 . In the specific embodiment shown in the figures, the ultrafine crystalline magnetic core 133 is a circular ring formed by a thin strip of amorphous material that is wound around one turn and then heat treated. The ultrafine crystal magnetic core 133 has excellent magnetic indicators, such as high permeability, high saturation magnetic induction, and low loss. However, since the amorphous strip becomes embrittled due to structural relaxation during heat treatment, the toughness similar to metallic glass is poor. When subjected to an external force, the ultrafine crystal magnetic core 133 is extremely sensitive to fracturing, and the soft magnetic performance will decrease accordingly, which will cause serious damage to the transformer 1, and poor accuracy of the transformer 1 will cause inaccurate meter readings. A thin strip of amorphous material is formed, for example, by solidifying an alloy melt comprising ferromagnetic elements and vitrifying elements at a cooling rate of 1 million degrees/second. In this way, the alloy is not only magnetic, but also has a lower melting point controllable, so it is easier to form amorphous. Specifically, the ferromagnetic elements include iron, cobalt, nickel, etc., and/or any combination thereof; The vitrifying elements may include silicon, boron, carbon, etc., and/or any combination thereof; Examples include Fe-Si-B, FeNiPB, CoZr, ZrTiCuNi, and the like. For the protection of the ultrafine crystal magnetic core 133, a protection box having a corresponding shape is used for preliminary protection, or a dip paint curing protection treatment is adopted. That is, the annular magnetic core 13 includes a magnetic core housing 132 and an ultrafine crystal magnetic core 133 accommodated in the magnetic core housing 132 . The magnetic core housing 132 is a ring shape coated on the outside of the ultrafine crystal magnetic core 133; The ultrafine crystal magnetic core 133 is immersed and hardened in the transformer 1 . The ultrafine crystal magnetic core 133 may be fixed in the magnetic core housing 132 with a soft adhesive or sponge. The magnetic core housing 132 has an annular shape matching the shape of the ultrafine crystal magnetic core 133 . A secondary current wire coil 14 is wound on a magnetic core housing 132 . The coil of the secondary current wire 14 may be electrically connected to a pair of lead wires 15 . Lead wires 15 extend past the transformer housing 10 to be electrically connected to a metering device 42 external to the transformer 1 . Although the ultrafine crystal magnetic core 133 is protected by the magnetic core housing 132 , the ultrafine crystal magnetic core 133 in the transformer 1 is easily damaged during handling, vibration, distortion, deformation and extrusion.

2 and 3 , the transformer housing 10 of the present invention includes a rigid material portion 11 and a flexible material portion 12 provided integrally. A ductile material refers to a material having a certain ductility and elasticity. The rigid material portion 11 and the soft material portion 12 together form an annular receiving cavity 101 having a closed bottom 103 . The annular receiving cavity 101 has an annular bottom wall 102 , an outer sidewall 112 surrounding the outer side of the annular bottom wall 102 , and an inner sidewall 122 surrounding the middle of the annular bottom wall 102 . include The annular magnetic core 13 is proximate to the annular bottom wall 102 , is sleeved on the outer side of the inner side wall 122 and received inside the outer side wall 112 . The annular receiving cavity 101 is filled with a packaging material 104 for holding the annular magnetic core 13 . The outer sidewall 112 is part of the rigid material portion 11 . The inner sidewall 122 is part of the soft material portion 12 . A through hole 123 is formed inside the inner sidewall 122 for the primary current wire 2 to pass therethrough. The inner sidewall 122 protrudes into the through hole 123 to resist the soft interference portion 124 interfering with the primary current wire 2 . The soft material portion 12 is made of a high temperature resistant material. In this way, the rigid material part 11 can achieve better structural stability and shape consistency for the transformer housing 10 . In different embodiments, the rigid material part 11 may be made of ABS, PVC, or PC materials. The flexible inner side wall 122 and the soft interference part 124 can realize the smooth passage of the primary current wire 2 and realize the anti-vibration and cushioning cooperation between the transformer 1 and the primary current wire 2 . Therefore, the anti-vibration protection of the ultrafine crystal magnetic core 133 inside the transformer 1 is realized, and the ultrafine crystal magnetic core 133 and the primary current due to various reasons of vibration and fracturing affecting the measurement accuracy. Collisions between the wires 2 are avoided. The rigid material and the soft material are integrated together such that the annular receiving cavity 101 has a closed bottom 103 . After the packaging material 104 is filled into the annular receiving cavity 101 , the bottom 103 has good airtightness. In general, the packaging material 104 may be an epoxy resin or other packaging materials. However, in this field, since the primary current wire 2 inside the transformer 1 needs to cycle a large current for a long time, it is easy to generate a lot of heat, and the transformer 1 needs to be in a high temperature environment. If the bottom 103 of the annular receiving cavity 101 has a gap, the packaging material 104 will easily flow out of the transformer housing 10 through the gap after being heated. If such a leak occurs, it will at least affect the accuracy of the measurement and will be prone to catastrophic power safety accidents such as fire. The high temperature resistant material may be rubber or silica gel. In this way, although the primary current wire 2 allows a large current to flow for a long time. The flexible inner sidewall 122 and the soft interference portion 124 will not be thermally damaged, which improves the safety of the transformer 1 in use. In addition, the soft interference portion 124 may be straight-toothed or other protruding shapes as long as it has a certain degree of ductility and elasticity.

Specifically, when the flexible material and the rigid material are disassembled into the integrated flexible and rigid transformer housing 10 , the rigid material portion 11 is an annular extending along the direction from the outer sidewall 112 toward the through hole 123 . a bottom end wall 111 . The annular bottom end wall 111 is provided with an intermediate hole 113 corresponding to the through hole 123 for the primary current wire 2 to pass therethrough. The soft material portion 12 includes an annular bottom plate 121 extending along a direction from the inner sidewall 122 to the outer sidewall 112 . The bottom end wall 111 and the bottom plate 121 are integrally formed with each other to form the annular bottom wall 102 . That is, in the present invention, soft and rigid materials are combined between the bottom end wall 111 and the bottom plate 121 , so that there is no gap between the bottom end wall 111 and the bottom plate 121 . When the packaging material 104 is heated, it will not leak out.

Specifically, reference may be made to FIGS. 4 and 10 to 13 showing schematic views of the bottom end wall 111 and the bottom plate 121 integrated with each other in the first and third embodiments of the present invention. The bottom end wall 111 is provided with a plurality of small cylinders 114 distributed around the outer side of the intermediate hole 113 . The annular bottom plate 121 is provided with a plurality of holes 125 distributed around the outer side of the inner sidewall 122 . Holes 125 are penetrated and fixed to small cylinders 114 . In this arrangement, after the holes 125 and the small cylinders 114 are inserted one by one, the bottom end wall 111 and the bottom plate 121 can be integrated with each other before packaging. The bottom end wall 111 and the bottom plate 121 are held tight and there is no possibility of lateral displacement or lateral separation from each other to cause a gap. This ensures that, after packaging, the packaging material 104 does not leak through any possible gaps, even if heated. In this way, the anti-vibration and anti-leakage adhesive functions of the ultrafine crystal magnetic core transformer 1 are realized.

In this regard, for manufacturing the transformer 1 of the above embodiments, the present invention provides a method for packaging and manufacturing the transformer 1 . The method for packaging and manufacturing the transformer 1 comprises the following steps:

A magnetic core 13 on which a rigid material part 11 and a flexible material part 12 as shown in FIG. 4 and a secondary current wire core 14 as shown in FIG. 3 are wound are respectively manufactured. The above steps do not distinguish before and after. As shown in FIG. 14 , the annular magnetic core 13 includes a magnetic core housing 132 and an ultrafine crystal magnetic core 133 housed in the magnetic core housing 132 . As shown in FIG. 4 , the rigid material portion 11 includes a bottom end wall 111 having an intermediate hole 113 and an outer sidewall 112 surrounding the bottom end wall 111 . The bottom end wall 111 is provided with a plurality of small cylinders 114 distributed around the outer side of the intermediate hole 113 . The soft material portion 12 includes a cylindrical hollow inner sidewall 122 and an annular bottom plate 121 extending outwardly from the inner sidewall 122 . A through hole 123 is formed inside the inner sidewall 122 for the primary current wire 2 to pass therethrough. The inner sidewall 122 protrudes into the through hole 123 to resist the soft interference portion 124 interfering with the primary current wire 2 . The soft material portion 12 is made of a high temperature resistant material. The annular bottom plate 121 is provided with holes 125 distributed around the outer side of the inner sidewall 122 .

Then, the annular bottom plate 121 is firmly attached to the bottom end wall 111, and the sealed bottom 103 is formed by allowing small cylinders 114 to extend through and secured to the holes 125. forming an annular receiving cavity 101 having;

assembling the annular magnetic core 13 on which the secondary current wire coil 14 is wound into the annular accommodating cavity 101;

Packaging material 104 is injected into the annular receiving cavity 101 to complete packaging.

In this way, the annular bottom plate 121 and the bottom end wall 111 can form a seamless fixed fit. After the annular magnetic core 13 is installed and packaged, the packaging material 104 passes the transformer housing 10 through any possible gap between the annular bottom plate 121 and the bottom end wall 111 after being heated for a long time. will not overflow. The integrated flexible and rigid transformer housing 10 can effectively protect the exterior of the transformer 1 . Besides, for the ultrafine crystal magnetic core transformer 1, it has excellent anti-vibration and anti-leak functions.

Furthermore, reference is made to Figs. 5 to 7 which are schematic views of the transformer housing 10 after the ultrasonic riveting process in the first embodiment of the present invention. After the rigid material part 11 and the soft material part 12 are positioned and combined, the small cylinders 114 are riveted with ultrasonic waves. The top of each small cylinder 114 extends integrally to cover the bottom plate 121 to prevent the bottom plate 121 from being separated from the cap 115 of the small cylinder 114 . In this arrangement, the cap 115 extending integrally with the bottom end wall 111 allows the bottom plate 121 to be extremely securely attached to the bottom end wall 111 without a seam. The cap 115 may also press the bottom plate 121 down from a peripheral position of the small cylinders 114 . Compared with the third embodiment, the riveting process of the first embodiment can make the rigid material part 11 and the soft material part 12 more compact. It can better ensure a seamless connection between the rigid material portion 11 and the flexible material portion 12 , and avoid leakage of adhesive at the bottom 103 of the transformer housing 10 .

Specifically, the riveting process involves performing ultrasonic waves on the small cylinders 114 in a method for packaging and manufacturing the transformer 1 after the hole 125 is penetrated and fixed in the small cylinders 114 . It refers to the inclusion of more. This causes the top of each small cylinder 114 to have a flat-shaped cap 115 extending integrally, so that the small cylinder 114 passes through the hole 125 and rivets the bottom plate 121 . Since the soft material is a high-temperature resistant material, when the small cylinders 114 are ultrasonically welded, the soft material can be prevented from causing large damage. The structure is stable after riveting, and excellent airtightness of the lower end 103 of the transformer housing 10 is achieved.

More preferably, reference is made to Figs. 8 to 10, which are schematic diagrams of the structure of the transformer housing 10 in the second embodiment of the present invention. The annular bottom plate 121 is built into and formed in the bottom end wall 111 . In this arrangement, the soft material portion 12 and the rigid material portion 11 have the perfect sealing properties of the bottom 103 during manufacturing and forming, and can achieve the best degree of leak-proof adhesive function.

Regarding the method of manufacturing the transformer 1 of the second embodiment, specific steps include:

An annular magnetic core 13 having a secondary current wire core 14 is fabricated. The annular magnetic core 13 includes a magnetic core housing 132 and an ultrafine crystal magnetic core 133 housed in the magnetic core housing 132;

The transformer housing 10 is simultaneously formed from two different soft and rigid materials by using a two-color plastic injection machine. The transformer housing 10 includes a rigid material portion 11 and a flexible material portion 12 . The soft material portion 12 includes a cylindrical hollow inner sidewall 122 and an annular bottom plate 121 extending outwardly from the inner sidewall 122 . A through hole 123 is formed on the inner side of the inner sidewall 122 for the primary current wire 2 to pass therethrough. The inner sidewall 122 is provided with a soft interference portion 124 which projects into the through hole 123 and is used to resist and impede the primary current wire 2 . The soft material portion 12 is a high temperature resistant material. The rigid material portion 11 includes a bottom end wall 111 having an intermediate aperture 113 and an outer sidewall 112 surrounding the bottom end wall 111 . The bottom plate 121 is injection molded to form an annular receiving cavity 101 having an inner sidewall 122 , an outer sidewall 112 , a bottom plate 121 and a bottom end wall 111 having a sealed bottom 103 . is embedded in the bottom end wall 111 by

assembling the annular magnetic core 13 on which the secondary current wire coil 14 is wound into the annular accommodating cavity 101;

Packaging material 104 is injected into the annular receiving cavity 101 to complete packaging.

In this way, the two-color plastic injection machine simultaneously molds the transformer housing 10 from two different flexible and rigid materials, such that the transformer housing 10 includes both the rigid material portion 11 and the flexible material portion 12 . do. In this way, it has excellent anti-vibration performance, and the annular receiving cavity 101 has the best airtightness of the lower end 103 . Even if the inside of the transformer 1 has a large leakage pressure after being heated, it can still be ensured that the packaging material 104 does not leak from the position between the rigid material portion 11 and the flexible material portion 12 . It completely avoids the possibility of electrical accidents caused by measurement errors and even here by leakage of the adhesive. It is worth noting that a “two-color plastic injection machine” refers to a device capable of completing the integrated injection molding of the transformer housing 10 at the same time, or before and after two or more materials. The device may consist of a complete device, or multiple devices may be combined or integrated with each other. Specifically, the rigid material portion 11 and the flexible material portion 12 may be injection molded together. Alternatively, as shown in FIG. 8 , the flexible material part 12 is first injected, and then the rigid material part 11 is injected out of the flexible material part 12 . For example, rubber parts or silicone parts are put into injection molds for injection. Alternatively, the rigid material part 11 is first partially injected, then the soft material part 12 is injected, and then the remaining part of the rigid material part 11 is injection molded.

As a further optimization, in the second embodiment as shown in FIG. 8 , the annular bottom plate 121 is provided with holes 125 distributed around the outer side of the inner sidewall 122 . The holes 125 are embedded in the bottom end wall 111 . In this arrangement, the rigid material portion 11 may be introduced into the apertures 125 during injection molding. After the injection molding is completed, the visceral adhesion between the soft material and the surrounding rigid material can be improved, and delamination between the materials is not easy to occur. Of course, in other embodiments of the invention similar to the second embodiment, the flexible material portion 12 may not be provided with holes 125 , or bottom plate 121 of other shapes may be used for injection molding. What is worth noting.

15 and 1 , the present invention also provides a power meter 4 . A wattmeter 4 is used to sample, meter and measure electrical parameters in the insulation. The wattmeter 4 includes a wattmeter casing 41 , a metering device 42 positioned within the wattmeter casing 41 , a metering display device 43 , and a wiring terminal box 44 . The wiring terminal box 44 is provided with a connection structure 100 between the transformer 1 and the wiring terminal 3 . The connection structure 100 of the transformer 1 and the wiring terminal 3 includes a transformer 1, a primary current wire 2 passing through the transformer 1, and a wiring terminal electrically connected to the primary current wire 2 3) is included. The wiring terminal 3 includes a main body 31 and a columnar body 32 extending forwardly from the main body 31 . The columnar body 32 has a connection hole 321 recessed from the columnar body 32 in the front-rear direction. The main body 31 is provided with a wiring hole 311 recessed from the main body 31 in the front-rear direction. The connection hole 321 and the wiring hole 311 face each other and do not communicate with each other. The primary current wire 2 passes through the connection hole 321 . In this way, the wattmeter 4 has a transformer 1 with an ultrafine crystal magnetic core 133 . The transformer 1 has anti-vibration and anti-leak properties, which greatly contributes to the stability of the measurement results of the power meter 4 and the safety of electricity use.

In a particular embodiment, the simultaneous forming of the transformer housing 10 from two different flexible and rigid materials by using a two-color plastic injection machine comprises first injection molding the flexible material portion 12, and then the flexible material inserting the part 12 into a mold to eject the rigid material part 11 outward. In this way, the annular bottom plate 121 of the flexible material part 12 is embedded in the rigid material part 11 .

Alternatively, the simultaneous forming of the transformer housing 10 from two different soft and rigid materials by using a two-color plastic injection machine comprises the outer sidewall 112 and the bottom end wall 111 of the rigid material portion 11 . first injection molding a portion of the lower end wall 111 , which is thinner. A soft material portion 12 is then formed on a portion of the bottom end wall 111 . Then, another part of the bottom end wall 111 is further injection molded on the outside of the annular bottom plate 121 of the flexible material part 12 , that is, the bottom end wall 111 is thickened. In this way, the annular bottom plate 121 of the flexible material part 12 is embedded in the rigid material part 11 .

The annular bottom plate 121 of the flexible material portion 12 is provided with a plurality of holes 125 distributed at intervals during forming. The holes 125 allow the rigid material portion 11 to pass through during injection molding. In this way, the soft material part and the rigid material part can be embedded and combined more stably.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art for the present invention. The terminology used in the description of the present invention is for the purpose of describing particular embodiments only, and is not intended to limit the present invention. As used herein, the term “or/and” includes any and all combinations of one or more related listed items.

Various technical features of the above-described embodiments may be arbitrarily combined for those skilled in the art. In order to simplify the description, not all possible combinations of the various technical features in the above-described embodiments are described. However, unless there is a contradiction in the combination of these technical features, it should be regarded as the scope of the present specification.

Although the foregoing embodiments represent only a few embodiments of the present invention, and the descriptions are more specific and detailed, they should not be construed as limiting the scope of the present invention. It should be pointed out that several modifications and improvements can be made for those skilled in the art without departing from the concept of the present invention, all of which fall within the protection scope of the present invention. Accordingly, the protection scope of the present invention shall be subject to the appended claims.

Claims (20)

A transformer used for sleeve on a primary current wire, the transformer comprising:
transformer housing;
an annular magnetic core housed within the transformer housing; and
a secondary current wire housed within the transformer housing and wound on the annular magnetic core;
The annular magnetic core includes an ultrafine crystal magnetic core, and the transformer housing includes a rigid material portion and a flexible material portion integrally arranged, wherein the rigid material portion and the flexible material portion are annular housing having a closed bottom. a cavity defining a cavity, wherein the annular receiving cavity includes an annular bottom wall, an outer sidewall surrounding a perimeter of the annular bottom wall, and an interior sidewall surrounding a middle of the annular bottom wall, the annular magnetic core comprising the proximate the annular bottom wall, sleeved on and received within the inner side of the outer sidewall, the outer sidewall being part of the rigid material portion, the inner sidewall being part of the flexible material portion, and The inner side of the inner sidewall defines a through hole for the primary current wire to pass through, the inner sidewall having a soft interference portion protruding into the through hole and used to resist and impede the primary current wire wherein the flexible material portion is a high temperature resistant material and the annular receiving cavity is filled with a packaging material for holding the annular magnetic core. The transformer according to claim 1, wherein the ultrafine crystal magnetic core is a circular ring made of a thin strip of amorphous material that is wound around one turn and then heat treated. The transformer of claim 2 , wherein the amorphous material is formed by solidifying an alloy melt comprising ferromagnetic elements and vitrifying elements at a cooling rate of 1 million degrees/second. 4. The method of claim 3, wherein: the ferromagnetic elements comprise iron, cobalt, nickel, and/or any combination thereof; wherein the vitrifying elements comprise silicon, boron, carbon, and/or any combination thereof. The magnetic core casing of claim 1 , wherein the annular magnetic core includes a magnetic core casing in which the ultrafine crystal magnetic core is accommodated, the magnetic core casing being in the shape of a circular ring wrapped around an exterior of the ultrafine crystal magnetic core. Transformers. The transformer of claim 1, wherein the ultrafine crystal magnetic core is immersed and hardened in the annular receiving cavity. 2. The method of claim 1, wherein the rigid material portion includes an annular bottom end wall extending along a direction from the outer sidewall to the through hole, the annular bottom end wall corresponding to the through hole and comprising: an intermediate aperture used for passing therethrough is provided, wherein the flexible material portion includes an annular bottom plate extending along a direction from the inner sidewall to the outer sidewall, the bottom end wall and the bottom plate being integrally arranged with each other and forming the annular bottom wall. 8. The lower end wall of claim 7, wherein the lower end wall is provided with a plurality of small cylinders distributed around the outer side of the intermediate hole, and the annular bottom plate is provided with a plurality of holes distributed around the outer side of the inner side wall, and , wherein the small cylinders extend through and are secured to the holes. 9. The transformer of claim 8, wherein the top of each small cylinder extends integrally with a cap covering the bottom plate to prevent the bottom plate from separating from the small cylinders. 8. The transformer of claim 7, wherein the annular bottom plate is insert molded into the bottom end wall. 11. The transformer according to claim 10, wherein the annular bottom plate is provided with holes distributed on the outer side of the inner sidewall, the holes being embedded in the bottom wall. A power meter comprising a power meter casing, a metering device, a metering display device, and a connection structure of a transformer and a wiring terminal,
the metering device, the metering display device and the connecting structure of the transformer and the wiring terminal are located in the power meter casing;
The connection structure of the transformer and the wiring terminal includes the transformer according to any one of claims 1 to 11, a primary current wire passing through the transformer, and a wiring terminal electrically connected to the primary current wire. The wiring terminal according to claim 12, wherein the wiring terminal includes a main body and a columnar body extending forwardly from the main body, the columnar body defining a connection hole recessed from the columnar body in a front-rear direction from the columnar body, the main body having the a wiring hole recessed along the front-rear direction from the main body is provided, the connection hole and the wiring hole are opposite to each other along the front-back direction and do not communicate with each other, and the primary current wire passes through the connection hole. A method for packaging and manufacturing a transformer according to any one of claims 1 to 7, comprising:
manufacturing an annular magnetic core on which a secondary current wire coil is wound, wherein the annular magnetic core includes the ultrafine crystal magnetic core;
manufacturing the transformer housing, the transformer housing comprising a rigid material portion and a flexible material portion integrally arranged, wherein the rigid material portion and the flexible material portion jointly form an annular receiving cavity having a closed bottom wherein the annular receiving cavity comprises an annular bottom wall, an outer sidewall surrounding a perimeter of the annular bottom wall, and an inner sidewall surrounding a middle of the annular bottom wall, the outer sidewall being part of the rigid material portion and , wherein the inner sidewall is part of the flexible material portion, the inner side of the inner sidewall defines a through hole for the primary current wire to pass through, the inner sidewall projecting into the through hole and resisting the primary current wire and a soft interference portion used to impede the wire is provided, the flexible material portion being a high temperature resistant material;
assembling the annular magnetic core on which the secondary current wire coil is wound into the annular receiving cavity; and
injecting the packaging material into the annular receiving cavity to complete the packaging. 10. A method for packaging and manufacturing a transformer according to any one of claims 1 to 9, the method for packaging and assembling the transformer comprising:
manufacturing an annular magnetic core on which the rigid material portion, the flexible material portion and the secondary current wire coil are wound, respectively; The annular magnetic core comprises the ultrafine crystal magnetic core, and the rigid material portion comprises a lower end wall having an intermediate aperture and an outer side wall surrounding an outer side of the lower end wall, the lower end wall including the A plurality of small cylinders are provided distributed around an outer side of the intermediate hole, the flexible material portion comprising an inner sidewall of a cylindrical hollow configuration and an annular bottom plate extending outwardly from the inner sidewall, the through hole including the primary formed on an inner side of the inner sidewall for a current wire to pass therethrough, the inner sidewall being provided with a soft interference portion protruding into the through hole and used to resist and impede the primary current wire; wherein the soft material portion is a high temperature resistant material, the annular bottom plate being perforated with holes distributed around the outer side of the inner sidewall;
firmly attaching the annular bottom plate to the bottom end wall and allowing the small cylinders to extend through and secured to the apertures to form an annular receiving cavity having a sealed bottom;
assembling the annular magnetic core on which the secondary current wire coil is wound into the annular receiving cavity; and
injecting the packaging material into the annular receiving cavity to complete the packaging. 16. The method of claim 15, wherein after allowing the small cylinders to extend through and secured to the bores, the method for packaging and manufacturing the transformer includes a flat-shaped cap integrally extending over the top of each small cylinder. and ultrasonically riveting the small cylinders to be provided, wherein the small cylinders pass through the holes and are then riveted to the bottom plate. 12. A method for packaging and manufacturing a transformer according to any one of claims 1, 10 and 11, comprising:
manufacturing an annular magnetic core on which a secondary current wire coil is wound, the annular magnetic core comprising an ultrafine crystal magnetic core;
simultaneously forming the transformer housing from two different flexible and rigid materials by using a two-color plastic injection machine, the transformer housing comprising the rigid material part and the flexible material part, the flexible material part being cylindrical hollow an inner sidewall of construction and an annular bottom plate extending outwardly from the inner sidewall, wherein the through hole is formed on the inner side of the inner sidewall for the primary current wire to pass therethrough, the inner sidewall includes the through hole a soft interference portion protruding into and used to resist and impede the primary current wire, the soft material portion is a high temperature resistant material, the rigid material portion includes a bottom end wall having an intermediate hole and the bottom and an outer sidewall surrounding the end wall, wherein the bottom plate is formed by injection molding such that the inner sidewall, the outer sidewall, the bottom plate and the bottom end wall form an annular receiving cavity having a sealed bottom. being built into the wall;
assembling the annular magnetic core on which the secondary current wire coil is wound into the annular receiving cavity; and
injecting the packaging material into the annular receiving cavity to complete the packaging. 18. The method of claim 17, wherein simultaneously forming the transformer housing from two different flexible and rigid materials by using the two-color plastic injection machine comprises first injection molding the flexible material portion, and then the flexible material portion inserting into a mold to extrude the rigid material portion outward; In this way, the annular bottom plate of the flexible material part is embedded in the rigid material part. 18. The method of claim 17, wherein the step of simultaneously forming the transformer housing from two different flexible and rigid materials by using the two-color plastic injection machine comprises first injection molding an outer sidewall of the portion of the rigid material and a portion of the bottom end wall. comprising the steps of; then, the flexible material portion is formed on a portion of the bottom end wall; Then, another part of the bottom end wall is further injection molded on the outside of the annular bottom plate of the flexible material part; In this way, the annular bottom plate of the flexible material part is embedded in the rigid material part. 18. The packaging transformer of claim 17, wherein the annular bottom plate of the flexible material portion is provided with a plurality of holes distributed at intervals during molding, the holes allowing the rigid material portion to pass through during injection molding and method for manufacturing.

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