A high-power inductor transformer structure

Abstract

The application relates to the field of electronic components, in particular to a large-power inductance transformer structure which comprises a bakelite framework, a middle shaft hole is formed through a top wall of the bakelite framework, first and second magnetic cores are arranged at two ends of the bakelite framework, a magnetic middle column of the first magnetic core and a magnetic middle column of the second magnetic core penetrate into the middle shaft hole and are butted; an inductive coil assembly is wound on the bakelite framework, a plurality of mounting holes are formed in the bottom of the bakelite framework, and the first end and the tail end of the inductive coil assembly are respectively welded on a PCB through insertion into the mounting holes. The application has the effects of improving the working efficiency of the transformer and reducing the loss.

Description

Technical Field

[0001] This application relates to the field of electronic components, and in particular to a high-power inductor transformer structure. Background Technology

[0002] In the field of power electronics technology, LED driver transformers generally adopt the traditional structure of bakelite frame and enameled wire. This traditional structure can play a certain role in low-power applications, but its limitations become increasingly apparent when facing high-power applications. With the increasing global emphasis on energy conservation and emission reduction, the industry has put forward more stringent requirements for the efficiency and loss of transformers. High-efficiency and low-loss transformers have become the key direction of development.

[0003] In existing technologies, two solutions are typically used to address the issues associated with high-power inductor transformers: one is to use a bakelite frame wound with enameled wire and soldered to the PCB board via frame pins. However, the pin material used in this method is mostly iron, which has high resistivity and will generate significant losses under high current conditions. The other solution is to use flying wires to connect thick-diameter enameled wires to avoid damage to the frame when the pins are attached. However, this method is complex to install, has low production efficiency, and the flying wire connection is prone to loosening, which in turn affects the reliability of the transformer.

[0004] The existing technology has obvious defects. Under high current conditions, the contact resistance of iron pins is high, which increases electrical losses. At the same time, thick-diameter enameled wires cannot be directly hung on the pins and can only be used in the form of flying wires, which is not only complicated to install, but also easy to damage the frame, making it difficult to meet the needs of large-scale production. Utility Model Content

[0005] In order to improve the working efficiency of transformers and reduce losses, this application provides a high-power inductive transformer structure.

[0006] This application provides a high-power inductive transformer structure, which adopts the following technical solution: A high-power inductor transformer structure includes a bakelite frame with a central shaft hole through the top wall. A first magnetic core and a second magnetic core are provided at both ends of the bakelite frame. The magnetic cores of the first magnetic core and the second magnetic core are inserted into the central shaft hole and connected. An induction coil assembly is wound around the bakelite frame. Multiple mounting holes are provided at the bottom of the bakelite frame. The first and last ends of the induction coil assembly are soldered to a PCB board through the mounting holes.

[0007] By adopting the above technical solution, the first and last ends of the induction coil assembly are directly inserted into the mounting holes at the bottom of the bakelite frame and soldered to the PCB board, avoiding the use of traditional pin connection methods, reducing contact resistance, and significantly reducing losses caused by high contact resistance under high power conditions, thereby improving the energy conversion efficiency of the transformer. At the same time, the direct insertion and soldering method simplifies the installation process, eliminating the need for additional pin installation, improving the working efficiency of the transformer and reducing losses.

[0008] Optionally, the induction coil assembly includes a first coil, a second coil, a third coil, a fourth coil, a fifth coil, and a sixth coil wound sequentially from the inside out on a bakelite frame, with adjacent coils being interlayered by insulating tape. The first coil and the fourth coil are connected in series to form a primary winding, the second coil and the fourth coil are connected in series to form a secondary winding, the third coil forms a primary winding, and the sixth coil forms an auxiliary winding.

[0009] By adopting the above technical solution, the induction coil assembly is designed as six coils wound sequentially from the inside out around a bakelite frame, with adjacent coils isolated by insulating tape layers to ensure electrical insulation between coils, prevent mutual interference, and improve the stability and safety of transformer operation. The first and fourth coils are connected in series to form the primary winding, and the second and fourth coils are connected in series to form the secondary winding. This series combination allows for flexible adjustment of the output voltage and current of the secondary winding according to actual needs, meeting the power requirements of different application scenarios. The third coil forms the primary winding, serving as the power input part, which can efficiently introduce external power into the transformer. The sixth coil forms the auxiliary winding, providing necessary power support or signal feedback for the transformer's internal control circuits, enabling the transformer to have more complete functions. Overall, this coil layout and winding formation method optimizes the electromagnetic conversion efficiency of the transformer, improves its performance and practicality, reduces losses under high current conditions, improves production efficiency and product consistency, and reduces the possibility of high resistivity of traditional iron pins, thus improving energy efficiency.

[0010] Optionally, the bakelite frame includes an upper end plate, a winding post, and a lower end plate. The upper end plate is connected to one end of the winding post, and the end of the winding post away from the upper end plate is connected to the lower end plate. The upper end plate and the lower end plate are protruding at both ends of the winding post, and the induction coil assembly is wound around the winding post.

[0011] By adopting the above technical solution, the structural design of the upper end plate, winding post, and lower end plate of the bakelite frame enables the protruding upper and lower end plates at both ends of the winding post to limit the induction coil assembly wound on the winding post, reducing displacement or loosening of the induction coil assembly during winding or use, enhancing the stability of the frame during winding, and further reducing the risk of frame damage during winding.

[0012] Optionally, two upper end plates are provided and distributed radially along the winding post. The outer wall of the winding post is connected to a positioning plate. The two upper end plates are connected through the positioning plate. The positioning plate is raised on the top of the upper end plate. The first magnetic core has a positioning groove for the positioning plate to pass through.

[0013] By adopting the above technical solution, two upper end plates are set along the radial distribution of the winding column and connected by a positioning plate. The first magnetic core has a positioning groove for the positioning plate to pass through, which can accurately determine the installation position of the first magnetic core relative to the bakelite frame, improve assembly accuracy, facilitate assembly operation, and improve production efficiency.

[0014] Optionally, the outer wall of the winding post is connected to a mounting plate, which is connected to the lower end plate, and mounting holes are made in the mounting plate.

[0015] By adopting the above technical solution, the mounting plate connected to the outer wall of the winding post is connected to the lower end plate, and the mounting holes are opened on the mounting plate. This allows for a more reasonable arrangement of the mounting positions of the beginning and end of the induction coil assembly, enabling the induction coil assembly to be accurately inserted into and soldered onto the PCB board through the mounting holes. This improves the accuracy and stability of the installation. At the same time, it makes the entire bakelite frame more uniformly stressed when bearing the induction coil assembly and connecting to the PCB board, further enhancing the strength of the frame during the winding process and greatly reducing the probability of frame damage.

[0016] Optionally, the mounting plate and the lower end plate are integrally molded.

[0017] By adopting the above technical solution, the mounting plate and the lower end plate are integrally molded, making the overall structure of the bakelite frame more stable and enhancing the strength of the frame. During the winding process, it can better resist the action of external forces, effectively reducing the risk of frame damage, and further improving production efficiency and product consistency. At the same time, the integrally molded structure reduces the connection process between the mounting plate and the lower end plate, making the installation process simpler and reducing assembly errors caused by component connection, thus reducing production steps and labor costs.

[0018] Optionally, the mounting plate is radially distributed along the winding post and protrudes from the bottom of the lower end plate to form a mounting groove that matches the second magnetic core.

[0019] By adopting the above technical solution, the second magnetic core can be accurately embedded in the mounting slot. The mounting slot plays a good limiting role for the second magnetic core, reducing displacement or shaking of the second magnetic core during installation and use. This improves the stability and reliability of the overall structure of the high-power inductor transformer, helps to reduce performance fluctuations that may be caused by changes in the magnetic core position, and thus improves the performance and quality of the product.

[0020] Optionally, the first magnetic core and the second magnetic core are fixed together with epoxy adhesive, and both the first magnetic core and the second magnetic core are covered with protective tape.

[0021] By adopting the above technical solution, the first and second magnetic cores are fixed together with epoxy adhesive, which can enhance the stability and firmness of the connection between the two, reduce the possibility of separation or displacement of the magnetic cores due to vibration or external force during use, ensure the stability of magnetic field transmission, and thus improve the efficiency and reliability of power conversion. At the same time, both the first and second magnetic cores are covered with protective tape, which can play a good role in insulation and protection, reduce the possibility of the magnetic cores being corroded by external environmental factors such as dust and moisture, and extend the service life of the magnetic cores.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. The first and last ends of the induction coil assembly are directly inserted into the mounting holes at the bottom of the bakelite frame and soldered to the PCB board, avoiding the use of traditional pin connection methods, reducing contact resistance. Under high power conditions, it can significantly reduce the loss caused by high contact resistance and improve the energy conversion efficiency of the transformer. At the same time, the direct insertion and soldering method simplifies the installation process, eliminating the need for additional pin installation, improving the working efficiency of the transformer and reducing losses. 2. The induction coil assembly is designed as six coils wound sequentially from the inside out around a bakelite frame, with adjacent coils isolated by insulating tape layers to ensure electrical insulation between coils, prevent mutual interference, and improve the stability and safety of transformer operation. The first and fourth coils are connected in series to form the primary winding, and the second and fourth coils are connected in series to form the secondary winding. This series combination allows for flexible adjustment of the output voltage and current of the secondary winding according to actual needs, meeting the power requirements of different application scenarios. The third coil forms the primary winding, serving as the power input part, which can efficiently introduce external power into the transformer. The sixth coil forms the auxiliary winding, providing necessary power support or signal feedback for the transformer's internal control circuits, enabling the transformer to have more complete functions. Overall, this coil layout and winding formation method optimizes the electromagnetic conversion efficiency of the transformer, improves its performance and practicality, reduces losses under high current conditions, improves production efficiency and product consistency, and reduces the possibility of high resistivity of traditional iron pins, thus improving energy efficiency. 3. This allows the second magnetic core to be accurately embedded in the mounting slot. The mounting slot provides good positioning for the second magnetic core, reducing displacement or shaking during installation and use. This improves the overall stability and reliability of the high-power inductor transformer, helps reduce performance fluctuations that may result from changes in the magnetic core's position, and ultimately enhances the product's performance and quality. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure in an embodiment of this application.

[0024] Figure 2 This is an exploded view of the overall structure in an embodiment of this application.

[0025] Figure 3 This is a schematic diagram of the induction coil assembly structure in an embodiment of this application.

[0026] Explanation of reference numerals in the attached figures: 1. Bakelite frame; 11. Upper end plate; 12. Winding post; 121. Central shaft hole; 13. Lower end plate; 14. Positioning plate; 15. Mounting plate; 151. Mounting hole; 2. First magnetic core; 3. Second magnetic core; 4. Induction coil assembly; 41. First coil; 42. Second coil; 43. Third coil; 44. Fourth coil; 45. Fifth coil; 46. Sixth coil. Detailed Implementation

[0027] The following is in conjunction with the appendix Figure 1-3 This application will be described in further detail.

[0028] This application discloses a high-power inductor transformer structure.

[0029] Reference Figure 1 A high-power inductor transformer structure includes a bakelite frame with a central shaft hole through the top wall. A first magnetic core and a second magnetic core are located at both ends of the bakelite frame. The magnetic cores of the first and second magnetic cores pass through and connect to the central shaft hole. An induction coil assembly is wound around the bakelite frame. Multiple mounting holes are provided at the bottom of the bakelite frame. The first and last ends of the induction coil assembly are soldered to a PCB board through these mounting holes, allowing current to flow more smoothly through the induction coil assembly, reducing contact resistance, and thus reducing losses under high current conditions. This also reduces the possibility of high resistivity issues associated with traditional pins, improving energy efficiency. Furthermore, this installation method is simpler and improves production efficiency.

[0030] The induction coil assembly includes a first coil, a second coil, a third coil, a fourth coil, a fifth coil, and a sixth coil wound sequentially from the inside out on a bakelite frame. Adjacent coils are insulated from each other by insulating tape. Specifically, the first coil is insulated from the second coil, the second coil from the third coil, the third coil from the fourth coil, the fourth coil from the fifth coil, and the fifth coil from the sixth coil by insulating tape. Furthermore, the outer wall of the sixth coil is also insulated from the external environment by insulating tape. In this example, polyimide insulating tape is used, which has advantages such as high temperature resistance and good insulation performance. The first coil and the fourth coil are connected in series to form the primary winding of the transformer, the second coil and the fourth coil are connected in series to form the secondary winding of the transformer, the third coil forms the primary winding of the transformer, and the sixth coil forms the auxiliary winding of the transformer.

[0031] Furthermore, the bakelite frame includes an upper end plate, a winding post, and a lower end plate. The upper end plate is fixedly connected to one end of the winding post and is fixed to the outer wall of the winding post. The winding post is used to wind the induction coil assembly. The induction coil assembly is wound around the winding post. The winding post is cylindrical to facilitate coil winding. A central hole is opened through the winding post. The end of the winding post away from the upper end plate is fixedly connected to the lower end plate and is fixed to the outer wall of the winding post. The upper end plate and the lower end plate are protruding at both ends of the winding post. The upper end plate and the lower end plate limit the induction coil assembly, reducing the possibility of the induction coil assembly slipping or shifting while wound on the winding post, thus ensuring the stable performance of the transformer.

[0032] The upper end plate is fan-shaped, and there are two upper end plates, which are radially distributed along the winding column. There is a gap between the two upper end plates. A positioning plate is fixedly connected to the outer wall of the winding column. The two upper end plates are fixedly connected by the positioning plate. The positioning plate is protruding on the top wall of the upper end plate, and the part of the positioning plate protruding from the upper end plate is in a 90° rotated figure-eight shape. The first magnetic core has a positioning groove for the positioning plate to pass through. When the positioning plate is inserted into the positioning groove, the positioning plate fits against the groove wall, thereby positioning the position of the positioning plate and improving the assembly accuracy and efficiency.

[0033] Furthermore, to reduce manufacturing costs, the shape of the lower end plate is consistent with that of the upper end plate, and two lower end plates are provided so that the lower end plates and the upper end plates are symmetrically arranged at both ends of the winding post.

[0034] Specifically, a mounting plate is fixedly connected to the outer wall of the winding post. The mounting plate is fixedly connected to the lower end plate. The two lower end plates are fixedly connected through the mounting plate. Mounting holes are opened in the mounting plate. The mounting plate is radially distributed along the winding post and is raised at the bottom of the lower end plate. This allows the raised parts of the two mounting plates to cooperate to form a mounting groove that matches the second magnetic core. The shape and size of the mounting groove are adapted to the second magnetic core. When the second magnetic core is installed in the mounting groove, a tight fit can be achieved, improving the stability of the structure.

[0035] In this example, there are eight mounting holes, arranged in groups of four on a mounting plate. The mounting holes in one group are evenly spaced and arranged in a straight line, with the arrangement direction perpendicular to the radial direction of the mounting plate. In the same group of four mounting holes, the first and last ends of the sixth coil are inserted into the two middle mounting holes, and the first and last ends of the third coil are inserted into the two end mounting holes. In another group of four mounting holes, the end of the second coil furthest from the fifth coil, the end of the first coil furthest from the fourth coil, the end of the fifth coil furthest from the second coil, and the end of the fourth coil furthest from the first coil are sequentially inserted into the four mounting holes.

[0036] Furthermore, the mounting plate and the lower end plate are integrally molded, making the overall structure of the bakelite frame more stable, enhancing the strength of the frame, and effectively reducing the risk of frame damage.

[0037] Specifically, the first and second magnetic cores are bonded together with epoxy adhesive. Epoxy adhesive has good bonding and insulation properties, which can ensure that the connection between the magnetic cores is firm and the electrical performance is stable. Both the first and second magnetic cores are covered with protective tape, such as high-temperature fiberglass tape, which can protect the magnetic cores and prevent them from being damaged by external factors during use. It also has certain insulation and heat insulation properties.

[0038] The implementation principle of a high-power inductor transformer structure in this application embodiment is as follows: the two ends of the first-stage winding, the second-stage winding, the primary winding, and the auxiliary winding are directly inserted into the mounting holes at the bottom of the bakelite frame and soldered to the PCB board, simplifying the installation process, eliminating the need for additional pin installation, improving the transformer's working efficiency and reducing losses. The unique structural design of the bakelite frame makes the winding process more convenient and less prone to damage to the frame, improving production efficiency and product consistency. The accurate installation and fixation of the first and second magnetic cores ensures the stability of the magnetic circuit, further improving the transformer's performance. Compared with the prior art, this structure has significant improvements in solving problems such as high current loss, winding difficulties, and complex installation, and can better meet the industry's demand for high-power inductor transformers.

[0039] The above are all preferred embodiments of this application. These embodiments are only explanations of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

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