Network transformer

Abstract

This application discloses a network transformer that addresses the problem of leakage inductance in the initial coupling region of signal lines, which affects signal transmission integrity. The transformer comprises a first winding, a second winding, a third winding, and a fourth winding twisted together to form a first twisted wire group, which is wound around a first magnetic ring at least one turn. The end of the first winding and the beginning of the third winding are twisted together on the outside of the first magnetic ring to form a first tap. The end of the second winding and the beginning of the fourth winding are twisted together on the outside of the first magnetic ring to form a second tap. The beginning of the second winding and the end of the fourth winding are twisted together on the outside of the first magnetic ring to form a second twisted wire group, which is wound around a second magnetic ring at least one turn. Specifically, at least both ends of the first twisted wire group are wound radially outside the first magnetic ring.

Description

Network transformer Technical Field

[0001] This application relates to the field of network signal transmission technology, and in particular to a network transformer. Prior Technology

[0002] In high-speed network equipment, the performance of the network transformer directly affects signal transmission quality. The leakage inductance problem at the primary coupling point of the signal line has remained unresolved. Although tapped crossovers can reduce leakage inductance at the taps, unavoidable unraveling of the windings in the primary coupling region prevents effective control of leakage inductance at this critical point. This leakage inductance significantly affects the integrity of high-frequency signal transmission and also negatively impacts the electromagnetic compatibility performance of the equipment. Summary of the Invention

[0003] This application provides a network transformer to solve the problem that leakage inductance, which affects the integrity of signal transmission, occurs in the initial coupling region of the signal line due to the unavoidable scattering of the winding.

[0004] This application provides a network transformer in several embodiments, including a first magnetic ring, a second magnetic ring, a first winding, a second winding, a third winding, and a fourth winding. The first winding, second winding, third winding, and fourth winding are twisted together to form a first stranded group, which is wound around the first magnetic ring at least one turn. The end of the first winding and the beginning of the third winding are twisted together on the outside of the first magnetic ring to form a first tap. The end of the second winding and the beginning of the fourth winding are twisted together on the outside of the first magnetic ring to form a second tap. The beginning of the second winding and the end of the fourth winding are twisted together on the outside of the first magnetic ring to form a second stranded group, which is wound around the second magnetic ring at least one turn. Specifically, at least both ends of the first stranded group are wound radially outside the first magnetic ring.

[0005] Optionally, along the length of the second stranded wire group, the end of the second stranded wire group closest to the first magnetic ring is the starting end. The second magnetic ring is rotated at least 180° relative to the first magnetic ring so that the starting end of the first winding, the end of the third winding, the first tap, the second tap, and the starting end of the second stranded wire group are twisted together.

[0006] Optionally, along the length of the second stranded wire group, the end of the second stranded wire group closest to the first magnetic ring is the starting end. The second magnetic ring is rotated at least 180° relative to the first magnetic ring so that the starting end of the first winding, the end of the third winding, the second tap, and the starting end of the second stranded wire group are wound and twisted around the first tap.

[0007] Optionally, on the radially outer side of the first magnetic ring, the two ends of the first stranded wire group are fixed by the beginning of the first winding and the end of the third winding in opposite directions.

[0008] Optionally, the number of turns at the beginning of the first winding is greater than or equal to 1 / 2 turn, the number of turns at the end of the third winding is greater than or equal to 1 / 2 turn, and the number of turns at the beginning of the first winding and the end of the third winding are the same.

[0009] Optionally, the number of turns of the first stranded wire group around the first magnetic ring is 2 to 5 or 5 to 7.

[0010] Optionally, the first stranded wire group is wound around the arc length region corresponding to the first magnetic ring with a central angle less than or equal to 270°.

[0011] Optionally, the number of turns of the second stranded wire group around the second magnetic ring is 2 to 5.

[0012] Optionally, the second stranded wire is wound around the arc length region corresponding to the central angle of the second magnetic ring, which is less than or equal to 180°.

[0013] Optionally, the twist rate of the first stranded wire group is 16 to 22 strands per inch.

[0014] Optionally, the twist rate of the first tap is 26 to 34 strands per inch.

[0015] Optionally, the twist rate of the second tap is 16 to 26 segments per inch.

[0016] Optionally, the twist rate of the second strand is 10 to 16 strands per inch.

[0017] Optionally, the network transformer also includes a fifth winding, the beginning of which is twisted together with the end of the second winding and the beginning of the fourth winding to form a second tap, and the end of which is twisted together with the beginning of the second winding and the end of the fourth winding to form a second stranded wire group.

[0018] Optionally, the diameter of the first magnetic ring is larger than the diameter of the second magnetic ring.

[0019] Optionally, the radial thickness of the first magnetic ring is less than or equal to 5 millimeters (mm).

[0020] Optionally, the end of the second tap is provided with a solder joint area with a length of 1 to 2 millimeters (mm).

[0021] The technical means provided in this application have the following advantages compared with the prior art:

[0022] In the network transformer provided in this embodiment, the second twisted wire group is twisted together at least through the beginning of the second winding and the end of the fourth winding to form a new wire bundle, and wound at least one turn on the second magnetic ring. Thus, at the first magnetic ring, the first and third windings of the first twisted wire group, together with the first tap, form a primary coil, and the second and fourth windings of the first twisted wire group, together with the second tap, form a secondary coil, thereby forming the main structure of the network transformer. This couples the differential signal from the Ethernet chip of the external unit to the other end of the connection line with different voltage levels through electromagnetic field conversion. Furthermore, the second twisted wire group wound on the second magnetic ring can serve as a common-mode rejection coil. When a differential-mode signal passes through the common-mode rejection coil, opposite magnetic fields are generated in the second magnetic ring and cancel each other out, forming low impedance or approximately no impedance, allowing useful differential-mode signals to pass through almost without loss. When a common-mode signal passes through the common-mode rejection coil, the same magnetic field is generated in the second magnetic ring and amplified, thereby superimposing and forming high impedance to suppress or absorb a large amount of common-mode interference signals, thus achieving the effect of suppressing signal interference.

[0023] Twisting and fixing refers to a self-locking structure formed by mechanically twisting two or more cables (or wire harnesses). It can also involve twisting a portion of the cables to fix the entire structure, thus fixing the first, second, third, and fourth windings close to the first magnetic ring. This allows the magnetic flux of the transformer structure to flow fully through the primary and secondary coils composed of the first, second, third, and fourth windings, thereby avoiding voltage drop losses due to leakage inductance that could affect the integrity of low-frequency and high-frequency signal transmission. In other words, through twisting and fixing, this application effectively reduces the leakage inductance intensity in the primary coupling region of the signal lines, reducing electromagnetic energy loss during high-frequency signal transmission. Simultaneously, the integrated twisting and winding process reduces production steps, shortens the manufacturing cycle of high-frequency coils, and provides a more reliable electromagnetic conversion component for high-speed network equipment. Simple Explanation of the Diagram

[0024] The drawings herein, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the specification, serve to explain the principles of this application.

[0025] To more clearly illustrate the technical means in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, those who are skilled in the art to which this application pertains can obtain other drawings based on these drawings without creative effort.

[0026] One or more embodiments are illustrated by way of example through the corresponding pictures in the drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are represented as similar elements. Unless otherwise stated, the figures in the drawings do not constitute a limitation on scale. Figure 1 is a schematic diagram of the structure of a network transformer in related technical means; Figure 2 is a schematic diagram of an ideal connection of the network transformer shown in Figure 1; Figure 3 is a schematic diagram of an actual connection of the network transformer shown in Figure 1; Figure 4 is an equivalent circuit diagram of the network transformer shown in Figure 1 under actual working conditions; Figure 5 is a partial structural schematic diagram of a network transformer provided in some embodiments of this application; Figure 6 is a schematic diagram of the structure of a first type of network transformer provided in some embodiments of this application; Figure 7 is an equivalent circuit diagram of the network transformer shown in Figure 6; Figure 8 is a schematic diagram of the network transformer shown in Figure 6 in a wire management state; Figure 9 is a schematic diagram of a winding structure of the network transformer shown in Figure 8; Figure 10 is a schematic diagram of the structure of a second type of network transformer provided in some embodiments of this application; Figure 11 is a schematic diagram of the first winding structure of the network transformer shown in Figure 10; Figure 12 is a schematic diagram of the second winding structure of the network transformer shown in Figure 10. Implementation

[0027] To make the objectives, technical means, and advantages of the embodiments of this application clearer, the technical means of the embodiments of this application will be clearly and completely described below with reference to the drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0028] The following provides numerous different embodiments or examples for implementing various structures of this application. Components and arrangements of specific examples are described below. Of course, these are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0029] For ease of description, spatial relative terms may be used in this text to describe the relative position or movement of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "below," "above," "front," "back," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure. For example, if the device in the figure undergoes a positional flip, orientation change, or change of motion, these directional indications will change accordingly. For instance, an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The device may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in this text will be interpreted accordingly.

[0030] In high-speed network equipment, the performance of the network transformer directly affects signal transmission quality. The leakage inductance problem at the initial coupling point of the signal line has remained unresolved. Although tapped crossovers can reduce leakage inductance at the taps, unavoidable unraveling of the windings in the initial coupling region prevents effective control of leakage inductance at this critical point. This leakage inductance significantly affects the integrity of high-frequency signal transmission and also negatively impacts the electromagnetic compatibility performance of the equipment.

[0031] For example, as shown in Figure 1, which is a schematic diagram of a network transformer in a related technical means. The windings around the transformer's magnetic coil are, in sequence, signal lines T1, T2, and T5, as well as tap lines T3 and T4. For example, signal line T1 can be one end of two blue cables, signal line T2 can be one end of two yellow cables, tap line T3 can be the other end of two blue and two yellow cables, tap line T4 can be one end of three cables (red, blue, and gold), signal line T5 can be the other end of a gold cable, signal line T6 can be the other end of a blue cable, and signal line T7 can be the other end of the three gold cables.

[0032] Based on this, refer to Figure 2, which is a schematic diagram of an ideal connection of the network transformer shown in Figure 1. In an ideal state, the magnetic flux in the transformer coil flows uniformly through signal line T5, tap line T4, signal line T6, signal line T1, tap line T3, and signal line T2, so that there is very little or no line loss during signal transmission.

[0033] However, in practical applications, the taps and signal lines cannot be fully coupled at the outer radial side of the transformer coil. Referring to Figure 3, which is a schematic diagram of an actual connection of the network transformer shown in Figure 1, this means that the magnetic flux in the transformer coil cannot completely pass through the secondary winding during actual operation, resulting in leakage inductances A1 and A2 at the secondary coil.

[0034] However, the equivalent circuit of a real network transformer increases line losses due to leakage inductance, as shown in Figure 4. Figure 4 is an equivalent circuit diagram of the network transformer shown in Figure 1 under actual operating conditions. The input load (IN) of the primary coil is Vin, and the output load of the secondary coil is: Vin-2×π·f·Lk×2.

[0035] As shown above, the output load of the secondary coil is inversely proportional to the leakage inductance Lk and the signal frequency f. Especially for high-frequency signals, the presence of leakage inductance Lk will cause a significant reduction in the output voltage of the secondary coil under high-frequency signals, thereby affecting the transmission integrity of high-frequency signals.

[0036] Based on this, please refer to Figures 5 to 12. This application embodiment provides a network transformer to solve the problem that leakage inductance, which affects the integrity of signal transmission, will inevitably occur in the initial coupling region of the signal line due to the unavoidable scattering of the winding.

[0037] As shown in Figures 5 and 6, the network transformer includes a first magnetic ring 10, a second magnetic ring 20, a first winding 1, a second winding 2, a third winding 3, and a fourth winding 4. The first winding 1, the second winding 2, the third winding 3, and the fourth winding 4 are twisted together to form a first stranded wire group 30, which is wound around the first magnetic ring 10 at least one turn.

[0038] Referring to Figure 5, the side of the first magnetic ring 10 facing outward along the axial direction is the front side, and the four windings located on the front side of the first magnetic ring 10 are its starting ends (such as the inlet ends). Correspondingly, the side of the first magnetic ring 10 facing away along the axial direction is the back side, and the four windings located on the back side of the first magnetic ring 10 are its ending ends (such as the outlet ends).

[0039] Referring to Figure 6, the end of the first winding 1 and the beginning of the third winding 3 are twisted together on the outside of the first magnetic ring 10 to form a first tap 40. The end of the second winding 2 and the beginning of the fourth winding 4 are twisted together on the outside of the first magnetic ring 10 to form a second tap 50. The beginning of the second winding 2 and the end of the fourth winding 4 are twisted together on the outside of the first magnetic ring 10 to form a second stranded wire group 60, which is wound around the first magnetic ring 10 at least one turn. The outside of the first magnetic ring 10 is the side radially away from the center of the first magnetic ring 10.

[0040] As shown in Figures 8 and 9, at least both ends of the first stranded wire group 30 are wound around the radial outer side of the first magnetic ring 10 to fix the signal lines such as the first winding wire 1, the second winding wire 2, the third winding wire 3 and the fourth winding wire 4 on the radial outer side of the first magnetic ring 10 through the winding method.

[0041] The first stranded wire group 30 refers to a composite wire bundle formed by four windings in a spiral twisting manner. This structure can enhance the electromagnetic coupling strength between the windings. For example, the four windings, the first winding 1, the second winding 2, the third winding 3 and the fourth winding 4, are twisted together to form a tightly coupled wire bundle. When this wire bundle is wound around the first magnetic ring 10 in a multi-turn manner, the mutual inductance between adjacent windings is enhanced.

[0042] The first tap 40 refers to the electrical connection node formed at a specific position outside the first magnetic ring 10 after the two windings, the end of the first winding 1 and the beginning of the third winding 3, are twisted together, so that the current path forms a closed loop on the surface of the magnetic ring. The second tap 50 refers to the electrical connection node formed at a specific position outside the first magnetic ring 10 after the two windings, the end of the second winding 2 and the beginning of the fourth winding 4, are twisted together, so that the current path forms a closed loop on the surface of the magnetic ring. The first tap 40 and the second tap 50 form a fixed connection point on the outside of the magnetic ring, so that the current flows along a predetermined path and avoids the windings shifting position on the surface of the magnetic ring.

[0043] Based on this, the second stranded wire group 60 is twisted together at least through the beginning of the second winding 2 and the end of the fourth winding 4 to form a new wire bundle, and is wound around the second magnetic ring 20 at least two turns.

[0044] Thus, referring to Figures 7 and 8, at the first magnetic ring 10, the first winding 1 and the third winding 3 in the first twisted wire group 30, together with the first tap 40, form the primary coil, and the second winding 2 and the fourth winding 4 in the first twisted wire group 30, together with the second tap 50, form the secondary coil, thereby forming the main structure of the network transformer. This couples the differential signal from the Ethernet chip of the external unit to the other end of the connection line with different voltage levels through electromagnetic field conversion. Furthermore, the second twisted wire group 60 wound on the second magnetic ring 20 can serve as a common-mode rejection coil. When a differential-mode signal passes through the common-mode rejection coil, opposite magnetic fields are generated in the second magnetic ring 20 and cancel each other out, forming a low impedance or approximately no impedance, allowing the useful differential-mode signal to pass through almost without loss. When a common-mode signal passes through the common-mode rejection coil, the same magnetic field is generated in the second magnetic ring 20 and amplified, thereby superimposing and forming a high impedance to suppress or absorb a large amount of common-mode interference signal, thus achieving the effect of suppressing signal interference.

[0045] Wrapping fixation refers to a self-locking structure formed by mechanically twisting two or more cables (or wire harnesses). It can also involve wrapping a portion of the cables to fix the entire structure. This fixes the first winding 1, second winding 2, third winding 3, and fourth winding 4 close to the first magnetic ring 10, allowing the magnetic flux of the transformer structure to flow fully through the primary and secondary coils formed by these four windings. This avoids voltage drop losses due to leakage inductance, which could affect the integrity of low-frequency and high-frequency signal transmission. In other words, through wrapping fixation, this application effectively reduces the leakage inductance intensity in the primary coupling region of the signal lines, reducing electromagnetic energy loss during high-frequency signal transmission. Simultaneously, the integrated twisting and wrapping process reduces production steps, shortens the manufacturing cycle of the high-frequency coil, and provides a more reliable electromagnetic conversion component for high-speed network equipment.

[0046] In this configuration, multiple signal lines and multiple taps are wound and fixed in various ways on the radially outer side of the first magnetic ring 10. This ensures that the first winding 1, the second winding 2, the third winding 3, and the fourth winding 4 wound on the first magnetic ring 10 can be stably close to the surface of the first magnetic ring 10 and be securely fixed.

[0047] For example, as shown in Figure 10, for the first stranded wire group 30, on opposite sides of the first magnetic ring 10 along the axial direction, the first winding 1, the second winding 2, the third winding 3 and the fourth winding 4 in the first stranded wire group 30 can be in a twisted state to make the primary coil and the secondary coil have a better electrical coupling strength.

[0048] Alternatively, as shown in Figure 5, on opposite sides of the first magnetic ring 10 along the axial direction, the first winding 1, second winding 2, third winding 3, and fourth winding 4 in the first stranded wire group 30 are not in a twisted state. In this case, through the signal wire and taps fixed and wound around the outside of the first magnetic ring 10, the first winding 1, second winding 2, third winding 3, and fourth winding 4 are made to be in close contact or adhered to the opposite sidewalls of the first magnetic ring 10 along the axial direction, and the distance between the first winding 1, second winding 2, third winding 3, and fourth winding 4 and the first magnetic ring is less than or equal to 0.8 mm. This maintains good electrical coupling strength between the primary and secondary coils, and the dispersed distribution of the first winding 1, second winding 2, third winding 3, and fourth winding 4 facilitates the subsequent twisting and braiding of the first tap 40, second tap 50, and second stranded wire group 60.

[0049] As shown in Figures 8 and 9, along the length of the second stranded wire group 60, the end of the second stranded wire group 60 closest to the first magnetic ring 10 is the starting end. Correspondingly, the end of the second stranded wire group 60 exposed after winding around the second magnetic ring 20 is the ending end. The second magnetic ring 20 is rotated at least 180° relative to the first magnetic ring 10 so that the starting end of the first winding 1, the ending end of the third winding 3, the first tap 40, the second tap 50, and the starting end of the second stranded wire group 60 are intertwined and bound together. The winding and binding angle of the above multi-strand wire bundle is greater than or equal to 180° to improve the tightness of the winding and binding.

[0050] Among them, winding and binding refers to a connection method in which multiple wires are wound in a spiral manner to form a composite conductor. Specifically, in the actual assembly process, the beginning of the first winding 1, the end of the third winding 3, the first tap 40, the second tap 50, and the beginning of the second twisted wire group 60 can be arranged side by side as a wire bundle. Then, by rotating the wire bundle or the first magnetic ring 10 clockwise (or counterclockwise), the individual wires or wire groups in the wire bundle are twisted and fixed together, similar to a twisted structure. This helps to reduce the leakage inductance intensity in the initial coupling area of ​​the signal lines, thereby reducing electromagnetic energy loss during high-frequency signal transmission. At the same time, the direct rotation and winding method simplifies the assembly process and helps to shorten the manufacturing cycle of the high-frequency coil.

[0051] Alternatively, the winding and binding method can use one of the signal lines or taps as the center of rotation, and then wind and fix the other cables around that center of rotation. The signal lines can also be fixed by twisting and winding them together.

[0052] For example, with the first tap 40 as the rotation center, the beginning of the first winding 1, the end of the third winding 3, the second tap 50, and the beginning of the second twisted wire group 60 can be distributed around the first tap 40 to form a wire bundle. Then, by rotating the wire bundle or the first magnetic ring 10 clockwise (or counterclockwise), each cable is wound around the outside of the first tap 40 with the first tap 40 as the rotation center, so that the beginning of the first winding 1, the end of the third winding 3, the second tap 50, and the beginning of the second twisted wire group 60 are twisted and twisted around the first tap 40, so that each cable or cable group in the wire bundle is twisted and fixed to the outside of the first tap 40. This helps to reduce the leakage inductance intensity in the initial coupling area of ​​the signal lines, thereby reducing electromagnetic energy loss during high-frequency signal transmission. At the same time, the direct rotation winding method simplifies the assembly process and helps to shorten the manufacturing cycle of the high-frequency coil.

[0053] In both of the above-mentioned winding and fixing methods, the twisting and winding angle can be any angle greater than or equal to 180°, such as 180°, 270°, 360° or higher, and can be flexibly set according to the actual winding and fixing effect. The twisted wire bundle can produce a circumferential covering effect on the first magnetic ring 10. This twisting and covering method enables the wires to form a closed electromagnetic circuit in the primary and secondary coupling regions, effectively suppressing the increase in leakage inductance caused by wire dispersion.

[0054] It should be noted that during the winding and twisting process, the first magnetic ring 10 can be fixed and the second magnetic ring 20 rotated, or the second magnetic ring 20 can be fixed and the first magnetic ring 10 rotated. In this case, rotating the first magnetic ring 10 allows the winding points of multiple wire harnesses and cables to be brought closer to the first magnetic ring 10, which helps reduce the leakage inductance in the initial coupling region of the signal lines.

[0055] Furthermore, other winding methods can also be used between the wire bundles on the radially outer side of the first magnetic ring 10. As shown in Figures 10, 11 and 12, on the radially outer side of the first magnetic ring 10, the two ends of the first stranded wire group 30 are wound and fixed in opposite directions by the beginning of the first winding 1 and the end of the third winding 3.

[0056] Here, the radial outer side of the first magnetic ring 10 refers to the outer circumferential surface area of ​​the first magnetic ring 10. Reverse winding means that the beginning of the first winding 1 and the end of the third winding 3 are wound in clockwise and counterclockwise directions respectively, which can be achieved using a synchronous reverse winding process.

[0057] For example, the beginning of the first winding 1 and the end of the third winding 3 start from both ends of the first stranded wire group and are wound in opposite directions around the remaining six cable portions at both ends of the first stranded wire group 30. Through reverse winding and tightening, the beginning of the first winding 1 and the end of the third winding 3 form a symmetrical winding distribution at the ends of the first stranded wire group 30 (i.e., outside the first magnetic ring 10), avoiding loosening of the stranded structure due to unidirectional winding. Simultaneously, the bidirectional tension generated by the reverse winding keeps the stranded wire group stably attached to the surface of the magnetic ring, preventing the winding from unraveling in the primary coupling region. This significantly reduces leakage inductance interference in the primary coupling region and improves the stability of high-frequency signal transmission. Furthermore, the symmetrical structure formed by the reverse winding simplifies the winding process control, avoiding the complex tension adjustment steps in traditional processes, which is beneficial for achieving large-scale and efficient production of high-frequency network transformers.

[0058] During the winding process through the first winding 1 and the third winding 3, the number of windings at the beginning of the first winding 1 is greater than or equal to 1 / 2 turn, the number of windings at the end of the third winding 3 is greater than or equal to 1 / 2 turn, and the number of windings at the beginning of the first winding 1 and the end of the third winding 3 are the same.

[0059] Having the same number of turns means that the distribution density and path of the two sets of windings at the coil are symmetrical, thereby ensuring a uniform distribution of magnetic flux near the first magnetic ring 10. Taking each turn as 360° of winding rotation as an example, greater than or equal to 1 / 2 turn means that the beginning of the first winding 1 and the end of the third winding 3 can each be wound around the two ends of the first strand group 30 by at least half a turn (i.e., rotated 180°) to tighten the wound bundle.

[0060] Specifically, when the beginning of the first winding 1 and the end of the third winding 3 are wound with the same number of turns, the two sets of windings form symmetrical current loops at both ends of the first stranded wire group 30, making the magnetic field distribution tend to be balanced. Furthermore, the winding fixation prevents a decrease in magnetic coupling efficiency in localized areas due to loose winding. This method, through a symmetrical winding design, allows the magnetic fields of the two sets of windings to compensate for each other. Simultaneously, by limiting the minimum number of winding turns, it ensures tight contact between the windings and the magnetic ring, avoiding parasitic capacitance effects caused by loose winding during high-frequency signal transmission.

[0061] Through the above-mentioned technical means, this application effectively reduces the leakage inductance in the primary coupling region, improves the integrity of signal transmission, simplifies the winding process, and makes the winding distribution more uniform and controllable, thereby improving the production efficiency and product consistency of high-frequency network transformers.

[0062] In some embodiments, the first stranded wire group 30 is wound around the first magnetic ring 10 2 to 7 times. For example, 2 to 5 times or 5 to 7 times.

[0063] The more turns the first strand 30 has, the better the response and common-mode rejection, and the better the EMI (Electromagnetic Interference) performance, meaning it has better anti-interference capabilities. Conversely, the fewer turns the first strand 30 has, the more suitable it is for high-speed signal transmission, with lower insertion loss and higher density, which is beneficial for overall miniaturization design.

[0064] Therefore, if the number of turns of the first twisted wire group 30 wound around the first magnetic ring 10 is less than 2, it will result in poor anti-interference performance. If the number of turns of the first twisted wire group 30 wound around the first magnetic ring 10 is greater than 7, it will result in a complex structure that is not suitable for the transmission of high-speed network signals. Therefore, the number of turns of the first twisted wire group 30 wound around the first magnetic ring 10 can be set to 2, 3, 4, 5, 6, or 7. For example, taking a network transformer suitable for a 2.5G network module as an example, the number of turns of the first twisted wire group 30 wound around the first magnetic ring 10 can be set to 7, which has good anti-interference capability. If the network transformer is suitable for a 10G network module, the number of turns of the first twisted wire group 30 wound around the first magnetic ring 10 can be set to 5, which maintains good anti-interference capability while being more suitable for the transmission of high-speed network signals.

[0065] Specifically, at the first magnetic ring 10, the first stranded wire group 30 is wound within an arc-length region corresponding to the central angle of the first magnetic ring 10 that is less than or equal to 270°. The first stranded wire group 30 is uniformly distributed circumferentially within the aforementioned arc-length region of the first magnetic ring 10.

[0066] By limiting the winding of the first stranded wire group 30 to cover the arc length area corresponding to the 270° central angle, the wires of the first stranded wire group 30 are symmetrically distributed at a specific angle on the surface of the first magnetic ring 10. This maintains the stability of the winding structure and prevents excessive dispersion of the wires in the unstretched areas. Through the coordinated control of the number of turns and the coverage angle, this winding method ensures that the windings of the first stranded wire group 30 form a uniform and compact arrangement on the surface of the first magnetic ring 10. While ensuring winding symmetry, it also provides operational space for tap connections.

[0067] At the second magnetic ring 20, the second stranded wire group 60 is wound around the second magnetic ring 20 2 to 5 times.

[0068] The second stranded wire group 60 wound on the second magnetic ring 20 is mainly used as a common-mode rejection coil to suppress or absorb a large amount of common-mode interference signals, thereby suppressing signal interference. The more turns the second stranded wire group 60 has, the better the response and common-mode rejection capability, and the better the EMI (Electromagnetic Interference) performance, i.e., the better the anti-interference capability. Conversely, the fewer turns the second stranded wire group 60 has, the more suitable it is for high-speed signal transmission, with lower insertion loss and higher density, which is beneficial for overall miniaturization design.

[0069] Therefore, if the number of turns of the second twisted wire group 60 around the second magnetic ring 20 is less than 2, it will result in poor anti-interference performance. If the number of turns of the second twisted wire group 60 around the second magnetic ring 20 is greater than 5, it will result in a complex structure that is not suitable for the transmission of high-speed network signals.

[0070] Based on this, the number of turns of the second twisted wire group 60 wound around the second magnetic ring 20 can be set to 2, 3, 4, or 5 turns. For example, taking a network transformer suitable for 2.5G and 10G network modules as an example, the number of turns of the second twisted wire group 60 wound around the second magnetic ring 20 can be set to 5 turns, which is more suitable for high-speed network signal transmission while maintaining good anti-interference ability.

[0071] Specifically, at the second magnetic ring 20, the second stranded wire group 60 is wound within an arc-length region of the second magnetic ring 20 with a central angle less than or equal to 180°. The second stranded wire group 60 is uniformly distributed circumferentially within this arc-length region of the second magnetic ring 20.

[0072] By limiting the winding of the second stranded wire group 60 to cover the arc length area corresponding to the 180° central angle, the conductors of the second stranded wire group 60 are symmetrically distributed at a specific angle on the surface of the second magnetic ring 20. This maintains the stability of the winding structure and prevents excessive dispersion of the conductors in the unstretched areas. Through the coordinated control of the number of turns and the coverage angle, this winding method ensures that the windings of the second stranded wire group 60 form a uniform and compact arrangement on the surface of the second magnetic ring 20. While ensuring winding symmetry, it also provides operational space for tap connections. This improves the utilization efficiency of the material of the second magnetic ring 20 and reduces leakage inductance problems caused by uneven winding distribution.

[0073] For the first stranded group 30, the second stranded group 60, the first tap 40, and the second tap 50 of the stranding configuration, the twisting degree of the first stranded group 30 can be set to 16 to 22 strands per inch.

[0074] The twist rate refers to the number of spiral twists per unit length of the stranded wire pair, which can be achieved by mechanically twisting the winding using a stranding machine. The twist rate range of the first strand group 30 is controlled by adjusting the twist density to balance the electromagnetic coupling efficiency and structural stability between the windings. By setting the first strand group 30 at a twist rate of 16 to 22 strands per inch, the winding can maintain a tight twisted state to enhance magnetic flux coupling, while avoiding stress concentration in the wire caused by excessive twisting.

[0075] For example, the twist rate of the first strand group 30 can be set to 16, 17, 18, 19, 20, 21, or 22 strands per inch. This can be flexibly set according to actual production arrangements and performance requirements, and there are no limitations on this.

[0076] Correspondingly, the twist rate of the first tap 40 can be set to 26 to 34 strands per inch. Thus, when the first tap 40 adopts a high twist rate of 26 to 34 strands per inch, the contact point density of the twisted wire pairs increases. For example, a synchronous twisting process of twisted pairs can be used, so that the tap part has stable electrical connection characteristics before the solder joint is formed.

[0077] It should be noted that this method uses differentiated twisting degree in different areas. A higher twisting degree is used at the first tap 40 to suppress wire fraying, while a moderate twisting degree is used at the first strand group 30 to maintain structural stability.

[0078] In some embodiments, as shown in Figures 6 and 10, the network transformer further includes a fifth winding 5, the first end of the fifth winding 5 being twisted together with the end of the second winding 2 and the first end of the fourth winding 4 to form a second tap 50, and the end of the fifth winding 5 being twisted together with the first end of the second winding 2 and the end of the fourth winding 4 to form a second stranded wire group 60.

[0079] The fifth winding 5 refers to the additional conductor connected between the second tap 50 and the second stranded wire group 60. Specifically, it can be made of enameled wire or insulated wire of the same material as the first winding, so as to enhance the mechanical stability between the windings through twisting. Twisting refers to multiple wires being wound in a spiral manner to form a combined conductor. Specifically, it can be achieved by a three-twisting process, which reduces leakage inductance caused by loose winding through physical contact.

[0080] By introducing a fifth winding 5, the beginning and end ends of both the second winding 2 and the fourth winding 4 are twisted together with the fifth winding 5, forming a stable three-twisted wire bundle structure. The windings remain twisted throughout the winding process of the magnetic ring, preventing a decrease in electromagnetic coupling efficiency due to dispersion. Furthermore, the introduction of the fifth winding 5 reduces the number of steps required to separately process the second winding 2 and the fourth winding 4, simplifying the production process.

[0081] Based on this, the twist rate of the second tap 50 is set to 16 to 26 segments per inch.

[0082] Correspondingly, the twist rate of the second strand group 60 can also be set to 10 to 16 strands per inch.

[0083] Since the second tap 50 serves as both a partial tap structure and a connecting section structure for the second stranded wire group 60, the twisting degree of the second tap 50 is positioned between that of the first tap 40 and the first stranded wire group 30. Simultaneously, the low twisting degree design of the second stranded wire group 60 allows for appropriate gaps to be maintained when the wire is wound on the second magnetic ring 20, for example, by using a single-axis stranding device to reduce stranding tension, thereby reducing the springback phenomenon of the winding after the magnetic ring is fixed.

[0084] This method employs differentiated stranding in different regions. Higher stranding is used at the taps to suppress wire unraveling, moderate stranding is used in the winding group area to maintain structural stability, and low stranding is used in the secondary winding group to reduce process complexity. This effectively reduces leakage inductance in the primary coupling region. The gradient stranding configuration ensures tight stranding at critical contact points, while also reducing the deformation risk of the first and second strand groups 30 and 60 during magnetic ring winding. This zoned control of stranding simplifies the manufacturing process of high-frequency coils; for example, stable electrical connections can be achieved at the taps without additional reinforcement, thereby improving production efficiency and product consistency.

[0085] In some embodiments, the end of the second tap 50 may be provided with a solder joint area with a length of less than or equal to 6 millimeters (mm).

[0086] The solder joint area refers to the area at the end of the wire where the insulation layer has been removed and tinned. This can be achieved by using a hot air gun for local heating combined with flux wetting. This area is used to ensure a reliable connection between the solder joint and the external circuit.

[0087] By providing a solder joint area of ​​up to 6 mm at the end of the second tap 50, and by pre-treating the ends of the wires to form a metallized surface, subsequent soldering processes do not require additional insulation stripping. This structural design maintains electrical connection reliability while avoiding the risk of wire damage caused by manual wire stripping in traditional processes. Furthermore, it allows for a more compact spatial distribution of the exposed conductors after stranding at the second tap 50, effectively suppressing electromagnetic field leakage caused by excessive conductor spacing during high-frequency signal transmission, thereby improving high-frequency signal transmission characteristics.

[0088] In some embodiments, the diameter of the first magnetic ring 10 is larger than the diameter of the second magnetic ring 20. Correspondingly, the radial thickness of the first magnetic ring 10 is less than or equal to 5 millimeters (mm). The radial thickness of the first magnetic ring 10 refers to the radial distance between the inner and outer circles in the cross-section of the magnetic ring, and can be specifically designed with a thin-walled structure to reduce material usage.

[0089] When the diameter of the first magnetic ring 10 is larger than the diameter of the second magnetic ring 20, the magnetic field distribution area of ​​the primary and secondary windings is expanded, allowing the winding spacing at the primary coupling point of the signal lines to be controlled, thus preventing increased leakage inductance due to winding spread. When the radial thickness of the first magnetic ring 10 is controlled to be less than 5 mm, the matching degree between the magnetic ring volume and the winding path is improved, which is beneficial for the winding to fit tightly against the surface of the magnetic ring. The combination or individual application of these two dimensional characteristics can optimize the distribution of the winding on the magnetic ring, thereby reducing energy loss during high-frequency signal transmission.

[0090] In the actual assembly process, the first winding 1, the second winding 2, the third winding 3, and the fourth winding 4 can be set to red, yellow, green, and blue enameled or coated wires, respectively, to facilitate the identification of the winding and connection of the circuit during assembly. Correspondingly, the fifth winding 5 can also be set to red enameled or red coated wire, without limitation.

[0091] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms "a," "an," and "described" as used herein may also include the plural forms. The terms "comprising," "including," "containing," and "having" are inclusive and therefore indicate the presence of the stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not construed as requiring them to be performed in a specific order as described or illustrated, unless the order of performance is explicitly indicated. It should also be understood that additional or alternative steps may be used.

[0092] Although terms such as first, second, third, etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another region, layer, or segment. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used in this document do not imply order or sequence. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as the second element, component, region, layer, or segment without departing from the teachings of the exemplary embodiments.

[0093] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

[0094] 1: First winding 2: Second winding 3: Third winding 4: Fourth winding 5: Fifth winding 10: First magnetic ring 20: Second magnetic ring 30: First stranded wire group 40: First tap 50: Second tap 60: Second strand group T1: Signal line T2: Signal Line T3: Tap Line T4: Tap Line T5: Signal Line T6: Signal Line T7: Signal Line A1: Leakage inductance A2: Leakage inductance IN: Input load Lk: Leakage inductance

Claims

1. A network transformer, comprising a first magnetic ring, a second magnetic ring, a first winding, a second winding, a third winding, and a fourth winding; the first winding, the second winding, the third winding, and the fourth winding are twisted together to form a first stranded group, the first stranded group being wound around the first magnetic ring at least one turn; the end of the first winding and the beginning of the third winding are twisted together on the outside of the first magnetic ring to form a first tap; the end of the second winding and the beginning of the fourth winding are twisted together on the outside of the first magnetic ring to form a second tap; the beginning of the second winding and the end of the fourth winding are twisted together on the outside of the first magnetic ring to form a second stranded group, the second stranded group being wound around the second magnetic ring at least one turn; wherein, At least both ends of the first stranded wire are wound around the radial outer side of the first magnetic ring.

2. The network transformer as described in claim 1, wherein, Along the length of the second stranded wire group, the end of the second stranded wire group closest to the first magnetic ring is the starting end; the second magnetic ring is rotated at least 180° relative to the first magnetic ring so that the starting end of the first winding, the ending end of the third winding, the first tap, the second tap and the starting end of the second stranded wire group are twisted together.

3. The network transformer as described in claim 1, wherein, Along the length of the second stranded wire group, the end of the second stranded wire group closest to the first magnetic ring is the starting end; the second magnetic ring is rotated at least 180° relative to the first magnetic ring so that the starting end of the first winding, the ending end of the third winding, the second tap, and the starting end of the second stranded wire group are wound and twisted around the first tap.

4. The network transformer as described in claim 1, wherein, On the radially outer side of the first magnetic ring, the two ends of the first stranded wire group are fixed by the beginning of the first winding and the end of the third winding in opposite directions.

5. The network transformer as described in claim 3, wherein, The number of turns at the beginning of the first winding is greater than or equal to 1 / 2 turn, the number of turns at the end of the third winding is greater than or equal to 1 / 2 turn, and the number of turns at the beginning of the first winding and the end of the third winding are the same.

6. The network transformer as described in claim 1, wherein, The number of turns of the first stranded wire around the first magnetic ring is 2 to 7; and / or, the first stranded wire is wound around the arc length region of the first magnetic ring with a central angle less than or equal to 270°.

7. The network transformer as described in claim 1, wherein, The second stranded wire is wound around the second magnetic ring 2 to 5 times; and / or, the second stranded wire is wound around the arc length region of the second magnetic ring with a corresponding central angle less than or equal to 180°.

8. The network transformer as described in claim 1, wherein, The first stranded wire has a twist rate of 16 to 22 strands per inch; and / or, the first tap has a twist rate of 26 to 34 strands per inch; and / or, the second tap has a twist rate of 16 to 26 strands per inch; and / or, the second stranded wire has a twist rate of 10 to 16 strands per inch.

9. The network transformer as described in any one of claims 1 to 8, wherein, The network transformer also includes: a fifth winding, the first end of which is twisted together with the end of the second winding and the first end of the fourth winding to form the second tap, and the end of the fifth winding is twisted together with the first end of the second winding and the end of the fourth winding to form the second stranded wire group.

10. The network transformer as described in any one of claims 1 to 8, wherein, The diameter of the first magnetic ring is greater than the diameter of the second magnetic ring; and / or the radial thickness of the first magnetic ring is less than or equal to 5 mm; and / or the end of the second tap is provided with a solder joint area with a length of less than or equal to 6 mm.

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