TWI641007B - Transformer manufacturing method capable of increasing output - Google Patents

Abstract

A method for manufacturing a transformer capable of increasing output, comprising: a preparation step of providing a first magnetic core and a second magnetic core; and a winding step of simultaneously using the two winding machines for the first magnetic core and The second magnetic core is wound; a center tapping step is to fix the first magnetic core and the second magnetic core in the winding step, and connect and short-circuit some terminal electrodes of different magnetic cores to form a transformer. The center tap; thereby, under the premise that the winding method is the same, the first core and the second core of the transformer of the invention can be simultaneously wound by two winding machines, so that the transformer can be more conventionally used. The method saves half of the winding time, and thus the invention can achieve the effects of improving production efficiency and output.

Description

Transformer manufacturing method capable of increasing output

The present invention relates to a method of manufacturing a transformer, and more particularly to a method of manufacturing a transformer capable of increasing throughput.

Common transformers vary in size depending on the designed capacitance. In addition to large-capacity transformers (such as those commonly used in power plants or utility poles), there are smaller, miniaturized transformers, inductors, or common mode filters installed inside electronic products. A conventional transformer, as disclosed in FIGS. 1 to 3 of the "Transformer" of the Republic of China Patent Publication No. I441211, includes a magnetic core composed of a drum core and a plate core, the drum core The first winding, the second winding, the third winding and the fourth winding are wound around, and the ends of each winding are electrically connected to the first to fourth terminal electrode pairs formed on the drum core, respectively. Thus, by providing the first to fourth land pattern pairs corresponding to the respective ends of the respective windings on a printed circuit board, the first land pattern pair and the second land pattern pair are simultaneously Shorting between the electrical paths and shorting the electrical path between the pair of third land patterns and the pair of fourth land patterns, after the magnetic core around each of the windings is mounted to the printed circuit board A transformer can be formed.

In the above technical solution, the transformer has a single drum core, that is, all the windings are wound on the same drum core, so that only a single one can be used in manufacturing the transformer. The winding machine is wound. According to the manufacturing technology of the existing winding equipment and transformer, when winding, usually only one winding can be wound at a time, and the fastest or the two windings can be wound at the same time. a group (for example, the first winding and the second winding are wound together, the third winding and the fourth winding are wound together), but even the latter, the total winding time is twice as long as the single winding time, therefore, The winding process of the existing transformer is time consuming, thereby reducing the production capacity and production efficiency of the product, and is not economical.

Therefore, how to improve the above-mentioned missing, that is, the technical difficulties that the applicant of this case wants to solve.

In view of the above problems existing in the existing transformer manufacturing process, it is an object of the present invention to develop a transformer manufacturing method which can improve production efficiency and output.

In order to achieve the above object, the present invention provides a transformer manufacturing method capable of improving throughput, comprising: a preparation step of providing a first magnetic core and a second magnetic core, the first magnetic core having a first winding portion And a pair of first flanges and second flanges respectively connected to the two ends of the first winding portion, the top surface of the first flange is provided with a first end electrode and a second end electrode, the second flange The top surface is provided with a third end electrode and a fourth end electrode in the same direction, the second core has a second winding portion and a pair of third flanges respectively connected to the two ends of the second winding portion And a fourth flange, the top surface of the third flange is provided with a fifth end electrode and a sixth end electrode in the same direction, and the top surface of the fourth flange is provided with a seventh end electrode in the same direction An eighth end electrode; a winding step, wherein the first magnetic core and the second magnetic core are respectively wound by two winding machines, and a first winding and a second winding are respectively separated Winding on the first winding portion of the first magnetic core, and respectively making the first end and the second end of the first winding Connected to the first end electrode and the fourth end electrode, the first end and the second end of the second winding are respectively connected to the second end electrode and the third end electrode, and a third winding and a first Four windings are respectively wound around the second winding of the second core a first end and a second end of the third winding are respectively connected to the fifth end electrode and the eighth end electrode, and the first end and the second end of the fourth winding are respectively connected to the line a sixth end electrode and a seventh end electrode; a center tapping step of fixing the first magnetic core and the second magnetic core in the winding step, and simultaneously making the second end electrode and the second magnetic core The fifth end electrode of the magnetic core is directly contacted and short-circuited, and the fourth end electrode of the first magnetic core and the seventh end electrode of the second magnetic core are directly contacted and short-circuited.

Wherein the first flange and the third flange are respectively located on the same side of the first magnetic core and the second magnetic core, and the second flange and the fourth flange are also respectively located on the first magnetic core and the second magnetic core The same side of the core.

Wherein, in the winding step, the two windings on the same magnetic core are wound by a bifilar winding or a single wire in a sequential manner.

After the center tapping step is completed, a cover plate is further fixedly combined with the bottom surface of each of the flanges of the first magnetic core and the bottom surface of each of the flanges of the second magnetic core.

The invention also provides a transformer manufacturing method for increasing the yield, comprising: a preparation step of providing a first magnetic core, a second magnetic core and a cover plate, the first magnetic core having a first winding portion and a first flange and a second flange respectively connected to the two ends of the first winding portion, the top surface of the first flange is provided with a first end electrode and a second end electrode, the second flange The top surface is provided with a third end electrode and a fourth end electrode in the same direction, the second magnetic core has a second winding portion and a pair of third flanges respectively connected to the two ends of the second winding portion a fourth flange, the top surface of the third flange is provided with a fifth end electrode and a sixth end electrode in the same direction, and the top surface of the fourth flange is provided with a seventh end electrode and a same direction Eighth end electrode; a winding In the wire step, the first magnetic core and the second magnetic core are respectively wound by two winding machines, and a first winding and a second winding are respectively wound around the first magnetic core. The first end and the second end of the first winding are respectively connected to the first end electrode and the third end electrode, and the first end and the second end of the second winding are respectively Connecting the second end electrode and the fourth end electrode, and winding a third winding and a fourth winding respectively on the second winding portion of the second magnetic core, and making the third winding The first end and the second end are respectively connected to the fifth end electrode and the seventh end electrode, and the first end and the second end of the fourth winding are respectively connected to the sixth end electrode and the eighth end electrode; The upper cover assembly step is performed by combining the cover plate with the bottom surface of each of the flanges of the first magnetic core and the bottom surface of each of the flanges of the second magnetic core, and the first magnetic core and the first magnetic core There is a gap between the two cores.

Wherein the first flange and the third flange are respectively located on the same side of the first magnetic core and the second magnetic core, and the second flange and the fourth flange are also respectively located on the first magnetic core and the second magnetic core The same side of the core.

Wherein, in the winding step, the two windings on the same magnetic core are wound by a bifilar winding or a single wire in a sequential manner.

The step of combining the upper cover further includes connecting the first end electrode and the fifth end electrode by using a first shorting element, and connecting the fourth end electrode and the eighth end electrode by using a second shorting element. Process.

Further, the first shorting element and the second shorting element are wires.

Thereby, under the premise that the winding method is the same, the first magnetic core and the second magnetic core of the transformer of the invention can be simultaneously wound by the two winding machines, thereby saving half of the conventional transformer manufacturing method. Winding time, which in turn enables the invention to achieve increased production efficiency and production The effectiveness of the amount.

〔this invention〕

1‧‧‧First core

11‧‧‧First winding department

12‧‧‧First flange

13‧‧‧second flange

14‧‧‧First-end electrode

15‧‧‧second end electrode

16‧‧‧Terminal electrode

17‧‧‧ fourth end electrode

2‧‧‧second core

21‧‧‧Second winding department

22‧‧‧ Third flange

23‧‧‧Fourth flange

24‧‧‧ fifth end electrode

25‧‧‧ sixth end electrode

26‧‧‧ seventh end electrode

27‧‧‧ eighth end electrode

3‧‧‧ solder

4‧‧‧ Cover

5‧‧‧ gap

6‧‧‧Circuit board

61‧‧‧First conductive line

62‧‧‧Second conductive line

71‧‧‧First short circuit component

72‧‧‧Second short circuit component

S1‧‧‧First winding

S2‧‧‧second winding

S3‧‧‧ third winding

S4‧‧‧fourth winding

S1a~S4a‧‧‧ first end

S1b~S4b‧‧‧ second end

The first figure is a flow chart of the steps of an embodiment of the present invention.

The second drawing is a schematic view showing the structure of each magnetic core in the preparation step of an embodiment of the present invention.

The third figure is a schematic view of the winding of each of the magnetic cores of the winding step of one embodiment of the present invention.

The fourth figure is a schematic diagram of the magnetic cores of one embodiment of the present invention combined into a transformer and completing the center tapping step.

The fifth drawing is a flow chart of the steps of the second embodiment of the present invention.

The sixth drawing is a schematic structural view of each of the iron core and the cover plate of the preparation step of the second embodiment of the present invention.

The seventh drawing is a schematic view showing the winding of each of the magnetic cores of the winding step of the second embodiment of the present invention.

The eighth drawing is a schematic view showing the combination of the respective magnetic cores of the upper cover assembly step of the second embodiment of the present invention and the cover plate.

The ninth drawing is a schematic structural view of a transformer of a second embodiment of the present invention welded to a circuit board having conductive lines for connecting different terminal electrodes to realize a center tap.

The tenth figure is a schematic structural diagram of the upper cover combining step of the second embodiment of the present invention further comprising the use of a short-circuiting element to connect the different terminal electrodes to realize the center tap.

Please refer to the first figure for the flow chart of the embodiment of the transformer manufacturing method of the present invention. The steps of the transformer manufacturing method of the present invention include: a preparation step, please refer to the second drawing, the preparation step is Providing a first magnetic core 1 and a second magnetic core 2, the first magnetic core 1 having a first winding portion 11 and a first flange 12 and a second flange 13 are respectively connected to the two ends of the first winding portion 11. The first surface of the first flange 12 is provided with a first end electrode 14 and a second end electrode 15. The top surface of the second flange 13 is provided with a third end electrode 16 and a fourth end electrode 17 in the same direction (herein, the so-called same direction means that the third end electrode 16 to the fourth end electrode The direction of 17 is the same as the direction from the first terminal electrode 14 to the second terminal electrode 15, and the bottom is the same), the second core 2 has a second winding portion 21 and a pair are respectively connected to the first a third flange 22 and a fourth flange 23 at two ends of the two winding portions 21, wherein the first flange 12 and the third flange 22 are respectively located on the same side of the first core 1 and the second core 2 The second flange 13 and the fourth flange 23 are also respectively located on the same side of the first core 1 and the second core 2, and the top surface of the third flange 22 is disposed in the same direction. There is a fifth terminal electrode 24 and a sixth terminal electrode 25, and the top surface of the fourth flange 23 is provided with a seventh terminal electrode 26 and an eighth terminal electrode 27 in the same direction; in an embodiment of the present invention In the second figure, the first magnetic core 1 and the second magnetic core 2 have the same shape and structure, and each of the magnetic cores may be a drum core, but not limited thereto. The terminal electrode may be an end silver layer, and may be formed on each of the magnetic cores by coating, electroplating, electroless plating, sputtering or other processes; and a winding step, please refer to the third figure. In the winding step, the first magnetic core 1 and the second magnetic core 2 are respectively wound by two winding machines (not shown), and a first winding S1 and a second winding are respectively performed. The winding S2 is wound around the first winding portion 11 of the first magnetic core 1 respectively, and the first end S1a and the second end S1b of the first winding S1 are respectively connected to the first end electrode 14 and The fourth end electrode 17, the first end S2a and the second end S2b of the second winding S2 are respectively connected to the second end electrode 15 and the third end electrode 16, and a third winding S3 and a fourth The winding S4 is wound around the second winding portion 21 of the second magnetic core 2, respectively, and the third winding is wound The first end S3a and the second end S3b of the line S3 are respectively connected to the fifth end electrode 24 and the eighth end electrode 27, and the first end S4a and the second end S4b of the fourth winding S4 are respectively connected to the sixth end The terminal electrode 25 and the seventh terminal electrode 26, that is, in the embodiment, the respective ends of the two windings of the same magnetic core are respectively connected to the respective cores in a diagonally interlaced manner. Above the terminal electrode; in one embodiment and the third figure of the present invention, each of the winding wires may be an enameled wire or other wire wires coated with an insulating layer on the outside of a copper wire, each of the winding wires and the magnetic core The connection of each terminal electrode can be realized by a process such as welding or hot pressing, and when winding, two windings on the same core can be wound by bifilar winding. Alternatively, the single wire may be wound in a sequential manner, and the latter may form a two-layer winding structure on the winding portion of the magnetic core, wherein the double wire winding may be sequentially aligned with the single wire. Winding saves half of the winding time, but the double-layer winding structure can make the winding have more turns. However, regardless of the winding method, the present invention can have the benefit of improving production efficiency compared to the conventional transformer manufacturing method using the same winding method. In addition, the specific structure and operation principle of the aforementioned winding machine And related software and hardware operating parameters are common knowledge in the field and are not the present invention, so it will not be described here; a center tapping step, please refer to the third and fourth figures, the center tapping step The first magnetic core 1 and the second magnetic core 2 that complete the winding step are combined and fixed, for example, adhesively bonded, while the second end electrode 15 of the first magnetic core 1 and the fifth end of the second magnetic core 2 are connected. The electrodes 24 are directly contacted and short-circuited, and the fourth terminal electrode 17 of the first core 1 and the seventh terminal electrode 26 of the second core 2 are directly contacted and short-circuited, thereby completing the transformer of the present invention. a manufacturing process, whereby the first magnetic core 1 and the second magnetic core 2 as a whole can be a transformer, wherein the second terminal electrode 15 and the fifth terminal electrode 24 and the fourth terminal electrode 17 are Seventh end electrode Both of them are respectively center taps of the primary side and the secondary side of the transformer due to a short circuit, and the first end electrode 14 and the sixth end electrode 25 and the third Both the terminal electrode 16 and the eighth terminal electrode 27 can serve as an input (Input, ie, primary side) and an output (Output, ie, secondary side) of the transformer, respectively. In this embodiment, the transformer of the present invention can be specifically used as A network transformer (or a transformer) is used, but the possible application range of the transformer of the present invention is not limited to this purpose; in addition, it can be mentioned that each end electrode is required to ensure short circuit There may be a good electrical connection between the two, and the present invention may further further solder a solder 3 such as solder between the second terminal electrode 15 and the fifth terminal electrode 24, and at the fourth terminal electrode 17 and the seventh end. Solder 3 is placed between the electrodes 26; in addition, please continue to refer to the fourth figure, in order to make the transformer of the present invention convenient for the SMT device suction to be mounted on the circuit board, after completing the above-mentioned center tapping step, Can enter one A cover plate 4 is respectively fixed (for example, adhered) to the bottom surface of each of the flanges of the first magnetic core 1 and the bottom surface of each of the flanges of the second magnetic core 2, that is, the cover plate The 4 series is fixed to the side of each of the magnetic cores facing away from the respective terminal electrodes (ie, the first to eighth terminal electrodes 14 to 17, 24 to 27), thereby making the cover plate 4 equivalent to The function of the transformer back film, so that the transformer can also omit an additional back film processing process, thereby making the invention more practical and convenient to use. In addition, in the fourth figure, the cover 4 is made of a single one. A larger planar plate body is formed. However, in other possible embodiments, two smaller planar plates (not shown) combined side by side may be used to form the cover plate 4.

Referring to the first to fourth figures, the present invention utilizes a winding method in which two individual magnetic cores are respectively wound and then combined into a complete and center-tapped transformer. Under the same premise, the transformer of the invention has the first core 1 and the first The two cores 2 can be wound by two winding machines at the same time. Therefore, the present invention can save half of the winding time by the conventional transformer manufacturing method, thereby enabling the invention to achieve the effects of improving production efficiency and output.

Please refer to the fifth figure for the flow chart of the second embodiment of the transformer manufacturing method of the present invention. The steps include: a preparation step, please refer to the sixth figure, the preparation step is provided. a magnetic core 1, a second magnetic core 2, and a cover 4, wherein the detailed structure of the first magnetic core 1, the second magnetic core 2, and the cover 4 of the embodiment is the first magnetic of the first embodiment The core 1, the second core 2, and the cover 4 can be said to be identical, so that the respective components and the cover 4 of the respective cores of the sixth drawing are given to the respective cores and covers of the first embodiment. 4 The same name and reference pull number are not repeated here; for a winding step, please refer to the sixth figure and the seventh figure, the winding step is performed by using two winding machines respectively. The magnetic core 1 and the second magnetic core 2 are wound, and a first winding S1 and a second winding S2 are respectively wound around the first winding portion 11 of the first magnetic core 1, and the The first end S1a and the second end S1b of the first winding S1 are respectively connected to the first end electrode 14 and the third end electrode 16, and the first end S2a and the second end of the second winding S2 S2b is respectively connected to the second terminal electrode 15 and the fourth terminal electrode 17, and a third winding S3 and a fourth winding S4 are respectively wound around the second winding portion 21 of the second core 2 And the first end S3a and the second end S3b of the third winding S3 are respectively connected to the fifth end electrode 24 and the seventh end electrode 26, and the first end S4a and the second end of the fourth winding S4 S4b is respectively connected to the sixth terminal electrode 25 and the eighth terminal electrode 27; an upper cover combination step, please refer to the seventh figure and the eighth figure, The upper cover assembly step is to fix (for example, adhere) the cover plate 4 to the bottom surface of each of the flanges of the first magnetic core 1 and the bottom surface of each of the flanges of the second magnetic core 2, that is, The cover plate 4 is fixedly disposed on a side of each of the magnetic cores facing away from the end electrodes (ie, the first to eighth end electrodes 14 to 17, 24 to 27), and the first magnetic core 1 is There is a gap 5 between the second cores 2 to prevent a part of the end electrodes of different magnetic cores from directly contacting each other due to the magnetic cores being in close contact with each other, thereby completing the manufacturing process of the transformer of the present embodiment, thereby Referring to FIG. 9 again, when the transformer of the embodiment is mounted on a circuit board 6, only one first conductive line 61 and one second conductive line 62 need to be respectively disposed on the circuit board 6, and The first conductive line 61 is used to connect the first end electrode 14 and the fifth end electrode 24, and the second conductive line 62 is used to connect the fourth end electrode 17 and the eighth end electrode 27, so that when the transformer is After the circuit board 6 is mounted and combined, the first end electrode 14 and the fifth end electrode 24 and the fourth end electrode 17 and the eighth The terminal electrodes 27 may serve as center taps of the primary side and the secondary side of the transformer, respectively, and the third terminal electrode 16 and the seventh terminal electrode 26 and the second terminal electrode 15 and the sixth terminal electrode 25 The two can be used as the input and output of the transformer respectively. In addition, please refer to the tenth figure, which is another technical solution for implementing the center tap in the present embodiment, which further includes the use of the first cover combination step. a first short-circuiting element 71 connecting the first terminal electrode 14 and the fifth terminal electrode 24, and connecting the fourth terminal electrode 17 and the eighth terminal electrode 27 by a second short-circuiting element 72, wherein The first shorting element 71 and the second shorting element 72 may specifically be wire wires as used for each of the windings, whereby the present embodiment can have the same effect of improving production efficiency and throughput as the first embodiment.

The detailed description of the preferred embodiments of the present invention is not intended to limit the scope of the present invention, but without departing from the spirit of the invention. Equivalent implementations or changes shall be included in the scope of the patent in this case.

Claims (9)

A method for manufacturing a transformer capable of increasing throughput, the method comprising: a preparation step of providing a first magnetic core and a second magnetic core, the first magnetic core having a first winding portion and a pair respectively connected to the first a first flange and a second flange at both ends of the winding portion, the top surface of the first flange is provided with a first end electrode and a second end electrode, and the top surface of the second flange is disposed in the same direction a third end electrode and a fourth end electrode, the second magnetic core has a second winding portion and a pair of third flanges and fourth flanges respectively connected to the two ends of the second winding portion, the first The top surface of the three flanges is provided with a fifth end electrode and a sixth end electrode in the same direction, and the top surface of the fourth flange is provided with a seventh end electrode and an eighth end electrode in the same direction; In the line step, the first magnetic core and the second magnetic core are respectively wound by two winding machines, and a first winding and a second winding are respectively wound around the first magnetic core. On the first winding portion, and connecting the first end and the second end of the first winding to the first end electrode and the fourth end, respectively An electrode, the first end and the second end of the second winding are respectively connected to the second end electrode and the third end electrode, and a third winding and a fourth winding are respectively wound around the second magnetic wire a second winding portion of the core, and connecting the first end and the second end of the third winding to the fifth end electrode and the eighth end electrode, respectively, the first end and the second end of the fourth winding The ends are respectively connected to the sixth end electrode and the seventh end electrode; a center tapping step is to fix the first magnetic core and the second magnetic core which are completed in the winding step, and at the same time make the second magnetic core The terminal electrode and the fifth terminal electrode of the second magnetic core are in direct contact with each other to be short-circuited, and the fourth end electrode of the first magnetic core and the seventh end electrode of the second magnetic core are directly contacted and short-circuited. The method for manufacturing a transformer according to claim 1, wherein the first flange and the third flange are respectively located on the same side of the first core and the second core, and the second flange is The fourth flanges are also respectively located on the same side of the first core and the second core. The method for manufacturing a transformer according to claim 1, wherein the winding step uses two-wire bifilar winding or single-line sequential for two winding systems on the same magnetic core. Winding around the way. The transformer manufacturing method according to claim 1, wherein after the center tapping step is completed, a cover plate and a bottom surface of each of the flanges of the first magnetic core and the second magnetic body are further respectively The bottom surface of each of the flanges of the core is combined and fixed. A method for manufacturing a transformer capable of increasing throughput, the method comprising: a preparation step of providing a first magnetic core, a second magnetic core, and a cover plate, the first magnetic core having a first winding portion and a pair a first flange and a second flange respectively connected to the two ends of the first winding portion, the top surface of the first flange is provided with a first end electrode and a second end electrode, and a top surface of the second flange a third end electrode and a fourth end electrode are disposed in the same direction, the second magnetic core has a second winding portion and a pair of third flanges and fourth portions respectively connected to the two ends of the second winding portion a flange, the top surface of the third flange is provided with a fifth end electrode and a sixth end electrode in the same direction, and the top surface of the fourth flange is provided with a seventh end electrode and an eighth direction in the same direction a first electrode; a winding step, wherein the first core and the second core are respectively wound by two winding machines, and a first winding and a second winding are respectively wound around the winding a first winding portion of the first magnetic core, and connecting the first end and the second end of the first winding to the first end And the third end electrode, the first end and the second end of the second winding are respectively connected to the second end electrode and the fourth end electrode, and a third winding and a fourth winding are respectively wound around a second winding portion of the second magnetic core, and connecting the first end and the second end of the third winding to the fifth end electrode and the seventh end electrode, respectively, the first of the fourth winding The second end and the second end are respectively connected to the sixth end electrode and the eighth end electrode; an upper cover combining step is respectively, respectively, the cover plate and the bottom surface of the first magnetic core and the second magnetic core The bottom surfaces of the flanges are combined and fixed, and a gap is formed between the first core and the second core. The transformer manufacturing method of claim 5, wherein the first flange and the third flange are respectively located on the same side of the first core and the second core, and the second flange is The fourth flanges are also respectively located on the same side of the first core and the second core. The method for manufacturing a transformer according to claim 5, wherein in the winding step, two windings are used for bifilar winding or single line sequential for two winding systems on the same magnetic core. Winding around the way. The method for manufacturing a transformer according to claim 5, wherein the step of combining the upper cover further comprises connecting the first end electrode and the fifth end electrode by using a first short-circuiting element, and utilizing a first The second shorting element connects the fourth terminal electrode and the eighth terminal electrode. A transformer manufacturing method according to claim 8, wherein the first short-circuiting element and the second short-circuiting element are wires.