WO2024037177A1

WO2024037177A1 - Winding device, transformer, and inductor

Info

Publication number: WO2024037177A1
Application number: PCT/CN2023/101593
Authority: WO
Inventors: 滕超; 黄伟琪
Original assignee: 合肥汉之和新材料科技有限公司
Priority date: 2022-08-18
Filing date: 2023-06-21
Publication date: 2024-02-22
Also published as: CN218004582U

Abstract

Provided are a winding device (10), a transformer, and an inductor. The winding device (10) comprises a plurality of metal sheet conductors (11) which are sequentially stacked to form the winding device (10), wherein each metal sheet conductor (11) is provided with a polyimide film layer (12) formed by an electrophoresis process. The film layer arranged on each metal sheet conductor (11) in the winding device (10) is a polyimide film layer (12) formed by an electrophoresis process, so that the thickness of the insulating film layer (12) on the outer surface of each metal sheet conductor (11) is greatly reduced, thereby reducing the overall size of the winding device (10), and making the structure of the winding device (10) more compact. In addition, the polyimide film layer (12) has good insulation, heat resistance, corona resistance, and the like, so that the space occupied by the winding device (10) can be greatly reduced while the winding device (10) has good working performance, thereby facilitating the miniaturization and high performance of the winding device (10), and thus facilitating wider application of the winding device (10).

Description

A winding device, transformer and inductor

This application claims priority to the Chinese patent application submitted to the China Patent Office on August 18, 2022, with the application number 202222177941.5 and the invention name "a winding device, transformer and inductor", the entire content of which is incorporated herein by reference. Applying.

Technical field

The present application relates to the technical field of circuit components, and in particular to a winding device, a transformer and an inductor.

Background technique

Winding devices are key components in various circuit components such as transformers and inductors and are widely used in the field of circuit equipment. For winding devices, they can be roughly divided into two types based on the different structures of their conductors. One is a winding formed by winding a conductor coil turn by turn, and the other is a winding formed by stacking flat conductors layer by layer.

Taking the winding device formed by stacking flat conductors as an example, in the actual application of winding devices, the surface of each flat conductor needs to be provided with insulating film layers and other film layers with various functions to ensure good working performance of the winding device. Although film layers with different functions can improve the working performance of winding devices to a certain extent, they also increase the thickness of each flat conductor to a certain extent, thereby increasing the space occupied by the winding devices.

Contents of the invention

The purpose of this application is to provide a winding device, a transformer and an inductor that, on the basis of good working performance, can greatly reduce the space occupied by the winding device, and are conducive to the miniaturization and high performance of the winding device. , thus facilitating the wider application of winding devices.

In order to solve the above technical problems, the present application provides a winding device, which includes a plurality of metal sheet conductors stacked in sequence to form a winding device; each metal sheet conductor is provided with a polyimide film layer formed by an electrophoresis process.

In an optional embodiment of the present application, the thickness of the polyimide film layer is 1 μm-250 μm.

In an optional embodiment of the present application, it also includes a magnetic core penetrating the inner ring of each metal sheet conductor.

In an optional embodiment of the present application, the surface of the magnetic core is provided with a second polyimide film layer formed by an electrophoresis process.

In an optional embodiment of the present application, the thickness of the second polyimide film layer is 1 μm-250 μm.

In an optional embodiment of the present application, the magnetic core is a ferrite core and/or a metal alloy core.

A transformer includes a winding device as described in any one of the above.

An inductor includes a winding device as described in any one of the above.

The present application provides a winding device, a transformer and an inductor. The winding device includes a plurality of metal sheet conductors stacked in sequence to form a winding device; each metal sheet conductor is provided with a polyimide film layer formed by an electrophoresis process.

The film layer provided on the metal sheet conductor in the winding device of the present application is a polyimide film layer formed by the electrophoresis process. That is to say, the polyimide film layer in the present application is directly attached to the metal sheet conductor. Compared with the conventional insulating film layer that is attached to a metal sheet conductor by being attached to an adhesive tape and wound around the metal sheet conductor, the polyamide layer structure is realized in this application without the aid of a glue layer or other adhesive layer. The adhesion of the imine film layer on the surface of the metal sheet conductor greatly reduces the thickness of the film layer attached to the surface of each metal sheet conductor, thereby reducing the overall volume of the winding device, making the structure of the winding device more compact and concentrated. The imide film layer has good insulation, heat resistance and corona resistance properties. As a result, the winding device in this application can greatly reduce the space occupied by the winding device on the basis of good working performance, which is conducive to the miniaturization and high performance of the winding device, and thus is conducive to a wider range of winding devices. Applications.

Description of drawings

In order to more clearly explain the embodiments of the present application or the technical solutions of the prior art, the following will briefly introduce the drawings needed to describe the embodiments or the prior art. Obviously, the drawings in the following description are only For some embodiments of the present application, those of ordinary skill in the art can also obtain other drawings based on these drawings without exerting creative efforts.

Figure 1 is a schematic structural diagram of a winding device provided by an embodiment of the present application;

Figure 2 is a partial cross-sectional structural diagram of the metal sheet conductor in Figure 1;

FIG. 3 is a schematic diagram of the magnetic core structure in the winding device provided by the embodiment of the present application.

Detailed ways

In conventional winding devices, the insulating film layer on the surface of the conductor is mostly wrapped around the conductor surface with a tape with an insulating layer on the surface, or the conductor surface is painted with an insulating paint layer to achieve the insulating film layer on the winding device. For the insulating layer wrapped with tape on the surface of the conductor, the tape with adhesive properties greatly increases the overall thickness of the insulating layer; and for the insulating layer formed in this way, as the use time of the winding device increases, the It is more prone to cracking problems, which will affect the service life of the entire winding device. For the insulating layer installed by painting the insulating paint layer, it is often difficult to ensure the uniformity of the thickness of the insulating paint layer. When flat conductors are stacked on top of each other, due to the uneven thickness of the insulating paint layer, each flat conductor will It is difficult to compactly stack the conductors, which also increases the thickness of the winding device to a certain extent.

Therefore, this application provides a technical solution for arranging a polyimide film layer formed by electrophoresis process on the metal sheet conductor in the winding device, which can reduce the space occupied by the winding device to a great extent. This makes the structure of the winding device more compact.

In order to enable those skilled in the art to better understand the solution of the present application, the present application will be further described in detail below in conjunction with the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some of the embodiments of the present application, but not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of this application.

Referring to Figures 1 and 2, Figure 1 is a schematic structural diagram of a winding device provided by an embodiment of the present application, and Figure 2 is a schematic partial cross-sectional structural diagram of the metal sheet conductor in Figure 1. FIG. 3 is a schematic diagram of the magnetic core structure in the winding device provided by the embodiment of the present application. The winding device 10 in this application may specifically include:

Multiple pieces are stacked in sequence to form the metal sheet conductor 11 of the winding device 10; each metal sheet conductor 11 is provided with a first polyimide film layer 12 formed by an electrophoresis process.

In the process of actually forming the first polyimide film layer 12 on the metal sheet conductor 11, First, a metal sheet conductor 11 with a substantially flat annular structure is formed, and then the first polyimide film layer 12 is formed on the metal sheet conductor 11 through an electrophoresis process.

Specifically, the surface of the metal sheet conductor 11 can be cleaned by alkali cleaning, pickling, solvent cleaning, laser cleaning or plasma cleaning; and then the cleaned metal sheet conductor 11 is completely immersed in the polyimide electrophoresis solution. , the polyimide electrophoresis solution is a mixture of polyimide, alkaline compounds, organic or inorganic fillers, alcohols or ketones, water-soluble polar solvents and deionized water; use the metal sheet conductor 11 as the positive electrode and apply voltage 20~80V, energize for electrophoresis, control the amount of charge by controlling the current and energization time, so that the amount of charge is 0.01~350C, by controlling the amount of charge, the polyimide film slowly grows on the surface of the metal sheet conductor 11, and the first Polyimide film layer 12; after the electrophoresis is completed, take out the metal sheet conductor 11 wrapped with the first polyimide film layer 12, use airflow to blow off the remaining electrophoresis liquid on the surface, and heat and dry it to form a film, and you can obtain The metal sheet conductor 11 has a first polyimide film layer 12 on its surface.

It should be noted that the electrophoresis process is a relatively common film growth process. The focus of this application is not on how to use the electrophoresis process to form the first polyimide film layer 12, but on the surface of the metal sheet conductor 11 of this application. The film layer structure of the first polyimide film layer 12 is a film layer structure that can be formed by the electrophoresis process. Therefore, the process and process principles of the electrophoresis process will not be introduced in detail in this embodiment. Refer to the conventional electrophoresis process. Just craftsmanship.

It can be seen that the first polyimide film layer 12 formed on the surface of the metal sheet conductor 11 using the electrophoresis process is directly attached and grown on the surface of the metal sheet conductor 11, and the metal sheet conductor 11 is an equal layer during the electrophoresis process. The potential body ensures that the thickness of the first polyimide film layer 12 formed on the surface of the metal sheet conductor 11 at different positions is uniform. The thickness of the first polyimide film layer 12 can be 1 μm-250 μm, because the first polyimide film layer 12 does not need to rely on other adhesive tapes to realize the first polyimide film. The layer 12 is adhered to the surface of the metal sheet conductor 11, thereby reducing the thickness of the insulation film on the surface of the metal sheet conductor 11 to a great extent. After the first polyimide film layer 12 is formed on the surface of the metal sheet conductor 11, each metal sheet conductor 11 can be stacked in sequence to form a winding device as shown in Figure 1. Because the thickness of the first polyimide film layer 12 on the surface of the metal sheet conductor 11 is greatly reduced compared to the thickness of the insulating film layer on the conductor surface of the conventional winding device, the space occupied by the winding device formed by stacking each metal sheet conductor 11 The size has also obviously been reduced to a great extent.

Compared with conventional winding devices in which a multi-layer film structure is provided on the conductor surface, only a single first polyimide film layer 12 needs to be provided in this application, which can effectively solve the problem of multi-layer adhesive insulating film layers. The phenomenon of film layer peeling that often occurs during electrical aging and thermal aging can also ensure the good working performance of winding devices.

The first polyimide film layer 12 itself is a good insulating material and thermal conductive material, which can have good insulating properties and is conducive to rapid heat dissipation of the metal sheet conductor 11; in addition, it only needs to be placed in the first polyimide film layer 12. During the electrophoretic growth process of the imide film layer 12, inorganic particles commonly used to improve the corona resistance of the material can be introduced into the polyimide electrophoresis solution to achieve the corona resistance of the first polyimide film layer 12. Improvement; for example, polymers and finely distributed alumina are common inorganic particles used to improve the corona resistance of the film layer, which will not be explained too much in this application.

In a specific embodiment of the present application, the thickness of the first polyimide film layer 12 on the surface of the metal sheet conductor 11 is set to 40 μm and 60 μm, and the first polyimide film layer with two different thicknesses is Conduct performance tests on the metal sheet conductors corresponding to the film layer 12. For example, you can conduct: voltage resistance characteristics test, insulation resistance test, corona resistance performance test, temperature index test, oil immersion resistance test, thermal conductivity test, thermal shock resistance test, softening impact test Wear temperature test, etc. The experimental results are shown in Table 1 below.

Table 1:

It can be seen from the above experimental data that when the thickness of the first polyimide film layer 12 of the winding device in this application is 60 μm, the withstand voltage can reach 10KV, and the insulation resistance reaches DC1kV and 5s. 17GΩ, leakage current DC2.7kV, less than 0.2μA in 60s, indicating that it has excellent insulation properties; breakdown field strength greater than 5kV, indicating that it has excellent electrical aging resistance; temperature index greater than 220℃, indicating that it has good electrical aging resistance Thermal aging resistance; the thermal conductivity is greater than 0.2W/m·K, indicating that it has good heat dissipation performance; resistance to oil immersion and thermal shock resistance, indicating that it has good resistance to oil immersion and thermal shock resistance.

Due to the existence of the first polyimide film layer 12, compared with insulating films made of other materials, its electrical aging resistance time is increased by at least 20 times, and the decomposition temperature is also increased by at least 20°C. Therefore, it has better electrical aging resistance and thermal aging resistance.

In addition, referring to FIG. 1 , it can be seen that each metal sheet conductor 11 is generally an annular structure with a through hole in the middle area. The metal sheet conductors 11 are stacked in sequence, and the through holes in the middle of each metal sheet conductor 11 can jointly form a cylindrical hole. Referring to FIG. 3 , in an optional embodiment of the present application, a magnetic core 20 penetrating the inner ring through hole of each metal sheet conductor 11 may be further provided in the cylindrical hole formed by each metal sheet conductor 11 .

Optionally, the magnetic core 20 may be a ferrite core (such as a manganese-zinc ferrite core, a nickel-zinc ferrite core, a magnesium-zinc ferrite core, etc.) and/or a metal alloy core ( For example, iron cores, iron-nickel alloy cores, silicon steel cores, amorphous alloy cores, nanocrystalline alloy cores, etc.).

Generally speaking, the material of the magnetic core 20 is relatively hard and has different shapes and often has sharp edges and corners. The existing insulation method of the magnetic core 20 is to use an insulating tape coating method to insulate it. During the coating process, due to process limitations, defects such as thin insulation and poor coating at corners and other irregular shapes are very easy to occur, and it is difficult to completely cover the internal space of the magnetic core. The insulating layer on the surface of the magnetic core often causes friction with the metal sheet conductor 11, causing damage to the insulating film.

To this end, in another optional embodiment of the present application, a second polyimide film layer formed through an electrophoresis process can be further provided on the surface of the magnetic core 20 . The thickness of the second polyimide film layer may be 1 μm-250 μm. Preferably, the thickness of the second polyimide film is 40 μm-90 μm.

It should be noted that when the winding device is used in inductors, transformers and other devices, there is a magnetic field in the magnetic core 20, and the losses caused by electromagnetic induction appear in the form of heat. Therefore, the insulating film layer of the magnetic core has heat resistance. Risk of failure due to poor performance. In this embodiment, the second polyimide film layer formed by electrophoresis process is used as the insulating layer of the magnetic core 20, which can not only reduce the thickness of the insulating layer on the surface of the magnetic core 20 to a certain extent, but also improve the insulation performance and ensure the The resistance of the insulation layer of the magnetic core 20 Thermal properties, thereby ensuring the working performance of the magnetic core 20.

To sum up, the conductors in the winding device in this application are metal sheet conductors, each metal sheet conductor is stacked in sequence to form the winding device, and the surface of each metal sheet conductor is provided with a polyimide film layer formed by an electrophoresis process; so that The surface of the conductor in this winding device can be directly attached with a single film layer, which can reduce the space occupied by the overall structure of the winding device on the basis of ensuring good working performance of the winding device, which is conducive to the miniaturization and high performance of the winding device. ization, thus facilitating the wider application of winding devices.

Based on the above embodiments of the winding device, this application further discloses a transformer, which may include any of the above winding devices.

Because the metal sheet conductor of the winding device is provided with a single layer of polyimide film layer formed by the electrophoresis process, the thickness of the winding device in the direction perpendicular to the metal sheet conductor can be reduced to a great extent, thereby improving the For a transformer using this winding device, a transformer with a flat structure can be formed, which is conducive to the wide application of the transformer in electronic devices such as tablet computers that require high thickness of the transformer.

It can be understood that winding components are not only key components in transformers, but also important components in inductors. To this end, in another optional embodiment of the present application, an inductor is further disclosed, which may include any of the above winding devices.

The inductor can also be widely used in electrical appliances or electronic equipment requiring a relatively small thickness of the inductor.

It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply that these entities or operations are mutually exclusive. any such actual relationship or sequence exists between them. Furthermore, the terms "comprises,""comprises," or any other variation thereof are intended to cover a non-exclusive inclusion such that elements inherent in a process, method, article, or apparatus include a list of elements. Without further limitation, an element defined by the statement "comprises a..." does not exclude the presence of additional identical elements in a process, method, article, or apparatus that includes the stated element. in addition, Among the above technical solutions provided by the embodiments of the present application, those parts that are consistent with the implementation principles of corresponding technical solutions in the prior art have not been described in detail to avoid excessive redundancy.

This article uses specific examples to illustrate the principles and implementation methods of this application. The description of the above embodiments is only used to help understand the method and its core idea of this application. It should be noted that for those of ordinary skill in the art, several improvements and modifications can be made to the present application without departing from the principles of the present application, and these improvements and modifications also fall within the protection scope of the claims of the present application.

Claims

A winding device, characterized in that it includes a plurality of metal sheet conductors stacked in sequence to form a winding device; each of the metal sheet conductors is provided with a first polyimide film layer formed by an electrophoresis process.
The winding device according to claim 1, wherein the thickness of the first polyimide film layer is 1 μm-250 μm.
The winding device according to claim 1, further comprising a magnetic core penetrating the inner ring of each metal sheet conductor.
The winding device according to claim 3, wherein a second polyimide film layer formed by an electrophoresis process is provided on the surface of the magnetic core.
The winding device according to claim 4, wherein the thickness of the second polyimide film layer is 1 μm-250 μm.
The winding device according to claim 3, characterized in that the magnetic core is a ferrite magnetic core and/or a metal alloy magnetic core.
A transformer, characterized by comprising the winding device according to any one of claims 1 to 6.
An inductor, characterized by comprising the winding device according to any one of claims 1 to 6.