A pin-type high-power pulse transformer and its preparation method

Abstract

The present invention discloses a pin-type high-power pulse transformer and a preparation method thereof, comprising a magnetic ring, an enameled wire, an inner layer of high temperature resistant insulating tape, a plastic base, a middle layer of high temperature resistant insulating tape and an outer layer of high temperature resistant insulating tape, the enameled wire adopts three layers of insulating wire, including a primary enameled wire and a secondary enameled wire, one end of the plastic base is open, a PIN needle is arranged on the open end of the plastic base, the outer surface of the magnetic ring is wound with the inner layer of high temperature resistant insulating tape, the primary enameled wire is wound outside the inner layer of high temperature resistant insulating tape, the middle layer of high temperature resistant insulating tape is wound outside the primary enameled wire, the secondary enameled wire is wound outside the middle layer of high temperature resistant insulating tape, the outer layer of high temperature resistant insulating tape is wound outside the secondary enameled wire, the magnetic ring after the enameled wire is wound constitutes a magnetic ring wire package, the magnetic ring wire package is placed in the plastic base and is fully encapsulated and fixed by epoxy resin covering, and the free end of the enameled wire head is electrically connected to the PIN needle. The present invention realizes high high voltage insulation resistance, and the final product can reach 20000V high voltage.

Description

Technical Field

[0001] The invention relates to a pin-type high-power pulse transformer and a preparation method thereof, belonging to the technical field of pulse transformers. Background Art

[0002] With the continuous expansion of the scientific research personnel team in my country, the continuous improvement and progress of scientific research technology, and the continuous innovation of electronic technology, the reliability requirements of electronic products are getting higher and higher. Miniaturization in structure and superior performance have become the trend of the manufacturing industry, which requires microwave magnetic devices to develop in the direction of short, small, light, thin, high electrical performance and high reliability. At present, according to the application field of pulse transformers and the new requirements of users for pulse transformers, they are large in size, heavy in weight, have no reinforcement plan, have complex structures that are not convenient for mounting, have low temperature resistance, and lack high voltage resistance, which can no longer meet the market demand for high reliability of pulse transformers. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a pin-type high-power pulse transformer and a preparation method thereof, so as to solve the technical problems existing in the prior art.

[0004] The technical solution adopted by the present invention is: a pin-type high-power pulse transformer, including a magnetic ring, an enameled wire, an inner layer of high-temperature resistant insulating tape, a plastic base, a middle layer of high-temperature resistant insulating tape and an outer layer of high-temperature resistant insulating tape, the enameled wire adopts three-layer insulating wire, including primary enameled wire and secondary enameled wire, one end of the plastic base is open, and a PIN needle is arranged on the open end of the plastic base, the outer surface of the magnetic ring is wrapped with the inner layer of high-temperature resistant insulating tape, the primary enameled wire is wrapped around the outside of the inner layer of high-temperature resistant insulating tape, the middle layer of high-temperature resistant insulating tape is wrapped around the outside of the primary enameled wire, the secondary enameled wire is wrapped around the outside of the middle layer of high-temperature resistant insulating tape, and the outer layer of high-temperature resistant insulating tape is wrapped around the outside of the secondary enameled wire. The magnetic ring after the enameled wire is wound constitutes the magnetic ring wire package of the semi-finished transformer, the magnetic ring wire package is placed in the plastic base and is covered with epoxy resin and fully encapsulated and fixed, and the free end of the enameled wire head is electrically connected to the PIN needle.

[0005] Preferably, the inner layer high temperature resistant insulating tape and the outer layer high temperature resistant insulating tape are both wound in double layers, the middle layer high temperature resistant insulating tape is wound in four layers, and after the outer and inner layers between two adjacent layers are wound, the outer layer is wound around the gap position of the inner layer.

[0006] Preferably, the magnetic ring is a circular magnetic ring.

[0007] Preferably, the magnetic ring is provided with an air gap.

[0008] Preferably, a mounting column is provided in the middle of the plastic base, and the mounting column is provided with a stepped through hole.

[0009] Preferably, the plastic base is provided with extension sections on both sides of the opening end, and grooves are provided at the corners.

[0010] Preferably, a U-shaped groove is provided at the location where the PIN pin is provided on the plastic base, and the U-shaped groove opens toward the inner side of the plastic base.

[0011] Preferably, the plastic base at the PIN pin is provided with a step, the step thickness is 3.5-4.5 mm, and the step height is 10-14 mm.

[0012] Preferably, the wall thickness of the plastic base is greater than 1 mm.

[0013] A method for preparing a pin-type high-power pulse transformer, the method comprising the following steps:

[0014] (1) Wrap the inner layer of high-temperature resistant insulating tape on the magnetic ring: Start from the tape on the left side of the air gap, start winding the wire counterclockwise to the air gap, then wind it back clockwise, with the wire ends on the left;

[0015] (2) The primary enameled wire of the three-layer insulated wire is wound around the inner layer of high-temperature resistant insulating tape. The enameled wire is threaded with a hook needle. The magnetic ring is fixed on the fixture, and the hook needle is used to pass through the magnetic ring and thread the wire back and forth in a clockwise direction.

[0016] (3) The enameled wire magnetic ring prepared in step (2) is immersed in varnish for the first time and placed on dust-free paper for 5 minutes; immersed in varnish for the second time and placed on dust-free paper for 5 minutes; immersed in varnish for the third time; baked for the first time at a temperature of 130°C and a baking time of 3 hours; immersed in varnish for the fourth time and placed on dust-free paper for 5 minutes; immersed in varnish for the fifth time and placed on dust-free paper for 5 minutes; baked for the second time at a temperature of 130°C and a baking time of 3 hours;

[0017] (5) Wrap the primary enameled wire with a middle layer of high temperature resistant insulating tape, then wrap the secondary enameled wire around the middle layer of high temperature resistant insulating tape, and wrap the outer layer of high temperature resistant insulating tape around the secondary enameled wire. The secondary enameled wire winding starts from the right side of the air gap and winds in a clockwise direction until it reaches 2 / 3 of the way, thus obtaining a finished enameled wire magnetic ring.

[0018] (6) The finished enameled wire magnetic ring prepared in step (5) is immersed in varnish for the first time and placed on dust-free paper for 5 minutes; immersed in varnish for the second time and placed on dust-free paper for 5 minutes; immersed in varnish for the third time; baked for the first time at a baking temperature of 130°C and a baking time of 3 hours; immersed in varnish for the fourth time and placed on dust-free paper for 5 minutes; immersed in varnish for the fifth time and placed on dust-free paper for 5 minutes; baked for the second time at a baking temperature of 130°C and a baking time of 3 hours.

[0019] Beneficial effects of the present invention: Compared with the prior art, the present invention has the following effects:

[0020] (1) The present invention uses three-layer insulated wire as the enameled wire material. The three-layer insulated wire can withstand a high voltage of 8000V. The multi-layer structure of high-temperature resistant insulating tape (inner layer, middle layer and outer layer of high-temperature resistant insulating tape winding structure) is added to enhance the high-voltage resistance. After the wire package is wound, it is immersed in varnish for multiple times to enhance its high-voltage insulation resistance. The final product can reach a high voltage of 20000V.

[0021] (2) The inner layer high temperature resistant insulating tape, the outer layer high temperature resistant insulating tape and the middle layer high temperature resistant insulating tape of the present invention are wound in such a way that after the outer and inner layers between two adjacent layers are wound, the outer layer is wound around the gap of the inner layer, so that the transformer can withstand high voltage more effectively;

[0022] (3) Although the square magnetic ring can also meet the use requirements, in the actual use process, the magnet will be used to interfere with the transformer. The square magnetic ring is placed around the base with a larger contact area, and the interference is stronger. Considering the anti-radiation ability, in the actual simulation test, the square magnetic ring waveform will be distorted, and the rising and falling edges are larger. The circular magnetic ring waveform is smoother and has no distortion. The rising and falling edges are better than the square magnetic ring. Therefore, the circular magnetic ring is selected. The circular magnetic ring has a smaller contact area with the edge of the base, so it has stronger anti-interference and anti-radiation capabilities;

[0023] (4) In actual application, high-power pulse transformers will generate large currents. Considering that the magnetic ring will be saturated, it will affect the normal operation of the product. In order to solve this problem, the magnetic ring can be treated with a 0.1mm air gap to prevent saturation;

[0024] (5) Since the entire volume of this high-power pulse transformer is relatively large, considering the actual application environment after assembly, high-intensity vibration, impact and other complex environments, a mounting column is provided in the middle of the plastic base, and the mounting column is provided with a step through hole. After the screw is passed through the step hole, the high-power pulse transformer is fixed to the circuit board to achieve a stable connection. The connection is more stable, and the step structure prevents the outer end of the screw from protruding from the plastic base;

[0025] (6) The extension section and the groove are provided to facilitate the last part of the glue pouring process to be close to the extension section or flow into the groove, thereby increasing the contact area between the glue pouring and the plastic base and improving the glue pouring adhesion;

[0026] (7) The step structure is set to take into account the installation reliability issue, especially the step thickening method designed at the PIN position, which can improve the plugging stability and reliability of the pin;

[0027] (8) A U-shaped groove 12 for clamping the wire is designed on the inner side of each foot position at the step of the plastic base 4, so that the wire end can be clamped in easily. The main functions are: first, to prevent the wires between the two adjacent pins from being connected together and causing the risk of short circuit; second, to clamp the wire into the wire groove, which is more beautiful and not messy;

[0028] (9) In order to ensure that the shell does not deform, the wall thickness of the plastic base 4 is more than 1 mm. The reason is that the design structure of this product is a square structure, considering the adaptability of the product in different ambient temperatures, such as high temperature application environment and low temperature application environment, considering the change of ambient temperature, thermal expansion and contraction, and considering the reliability due to its large size. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a three-dimensional structural schematic diagram of the present invention;

[0030] Figure 2 It is a bottom-up structural schematic diagram of the present invention;

[0031] Figure 3 It is a schematic diagram of the cross-sectional structure of the magnetic ring. DETAILED DESCRIPTION

[0032] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0033] Example 1: Figure 1-Figure 3 As shown, a pin-type high-power pulse transformer includes a magnetic ring 1, an enameled wire 2, an inner layer of high-temperature resistant insulating tape 3, a plastic base 4, a middle layer of high-temperature resistant insulating tape 6 and an outer layer of high-temperature resistant insulating tape 7. The enameled wire 2 adopts a three-layer insulating wire, including a primary enameled wire and a secondary enameled wire. One end of the plastic base 4 is open, and a PIN needle 5 is arranged on the open end of the plastic base 4. The outer surface of the magnetic ring 1 is wrapped with the inner layer of high-temperature resistant insulating tape 3, the primary enameled wire is wrapped around the inner layer of high-temperature resistant insulating tape 3, the middle layer of high-temperature resistant insulating tape 6 is wrapped around the primary enameled wire, the secondary enameled wire is wrapped around the middle layer of high-temperature resistant insulating tape 6, and the outer layer of high-temperature resistant insulating tape 7 is wrapped around the secondary enameled wire. The magnetic ring 1 after the enameled wire 2 is wound constitutes a semi-finished magnetic ring wire package of the transformer. The magnetic ring wire package is placed in the plastic base 4 and is covered and fully encapsulated with epoxy resin, and the free end of the wire head of the enameled wire 2 is electrically connected to the PIN needle 5.

[0034] Preferably, the inner layer high temperature resistant insulating tape 3 and the outer layer high temperature resistant insulating tape 7 are both wound in double layers, the middle layer high temperature resistant insulating tape 6 is wound in four layers, and after the outer and inner layers between two adjacent layers are wound, the outer layer is wound around the gap position of the inner layer.

[0035] Preferably, the magnetic ring 1 is a circular magnetic ring, and the magnetic ring 1 is provided with an air gap 8. The main functions of this high-power pulse transformer are 3:1 voltage transformation, output signal driving thyristor, radiation resistance, and instantaneous high voltage resistance. This high-power transformer is mainly a thyristor, which is a four-layer structure (PNPN) high-power semiconductor device, also known as a controlled rectifier or a thyristor element, and it has three lead electrodes, namely, an anode (A), a cathode (K), and a gate (G). When designing, according to the actual application, there are two modes: 24V to 8V or 12V to 3V. The transformation ratio of the high-power pulse transformer is designed to be 3:1. In terms of material selection, since it is driven by a high-power pulse signal and has the requirements of anti-radiation and anti-interference, ferrite power material is selected. The square magnetic ring can also meet the use requirements, but in the actual use process, magnets will be used to interfere with the transformer. The square magnetic ring is placed around the base with a larger contact area, and the interference is stronger. Considering the anti-radiation ability, in the actual simulation test, the square magnetic ring waveform will be distorted, the rising and falling edges are larger, and the circular magnetic ring waveform is smoother and has no distortion. The rising and falling edges are better than the square magnetic ring, so the circular magnetic ring is selected. The circular magnetic ring has a smaller contact area with the edge of the base, so the anti-interference ability and anti-radiation ability are stronger. In addition, large currents will be generated in actual applications. Considering that the magnetic ring will be saturated, affecting the normal operation of the product, in order to solve this problem, the magnetic ring can be treated with a 0.1mm air gap to prevent saturation.

[0036] Since the entire volume of this high-power pulse transformer is relatively large, considering the actual application environment after assembly, high-intensity vibration, impact and other complex environments, a mounting column 9 is arranged in the middle of the plastic base 4, and the mounting column 9 is provided with a stepped through hole. After the screw is passed through the stepped hole, the high-power pulse transformer is fixed to the circuit board to achieve a stable connection with better connection stability. The stepped structure prevents the outer end of the screw from protruding from the plastic base.

[0037] Preferably, the plastic base 4 is provided with extension sections 10 on both sides of the opening end and grooves 11 at the corners, so that the last part of the glue pouring process is close to the extension section or flows into the groove, increasing the contact area between the glue pouring and the plastic base and improving the glue pouring adhesion.

[0038] Preferably, a step 13 is provided on the plastic base 4 at the above-mentioned PIN pin 5, with a thickness of 3.5-4.5 mm and a height of 10-14 mm, which occupies 1 / 3 of the height of the entire plastic base. This structure is designed with installation reliability issues in mind, and a step thickening method is especially designed at the PIN pin position to improve the plug-in stability and reliability of the pin.

[0039] Preferably, a U-shaped groove 12 is provided at the PIN pin 5 of the plastic base 4, and the U-shaped groove 12 opens toward the inner side of the plastic base 4. A U-shaped groove 12 for clamping the wire is designed on the inner side of each pin position at the step of the plastic base 4, so that it is convenient to clamp the wire end in. The main functions are: first, to prevent the wires between the two adjacent pins from being connected together to cause the risk of short circuit, and second, to clamp the wire into the wire groove, which is more beautiful and less messy.

[0040] In order to ensure that the shell does not deform, the wall thickness of the plastic base 4 is more than 1 mm. The reason is that the design structure of this product is a square structure, considering the adaptability of the product under different ambient temperatures, such as high temperature application environment and low temperature application environment, considering the change of ambient temperature, thermal expansion and contraction, and considering the reliability due to its large size.

[0041] Embodiment 2: A method for preparing a pin-type high-power pulse transformer, the method comprising the following steps:

[0042] (1) Wrap the inner layer of high-temperature resistant insulating tape on the magnetic ring: Start from the tape on the left side of the air gap, start winding the wire counterclockwise, wind it to the air gap, and then wind it back clockwise, with the wire ends on the left. Wrap the magnetic ring with high-temperature insulating tape. Wrap the magnetic ring with a thick layer of high-temperature tape to enhance its withstand voltage.

[0043] (2) The primary enameled wire of the three-layer insulated wire is wound around the inner layer of high-temperature resistant insulating tape. The enameled wire is threaded with a hook needle. The magnetic ring is fixed on the fixture, and the hook needle is used to pass through the magnetic ring and thread the wire back and forth in a clockwise direction.

[0044] (3) The enameled wire magnetic ring prepared in step (2) is immersed in varnish for the first time and placed on dust-free paper for 5 minutes; immersed in varnish for the second time and placed on dust-free paper for 5 minutes; immersed in varnish for the third time; baked for the first time at a temperature of 130°C and a baking time of 3 hours; immersed in varnish for the fourth time and placed on dust-free paper for 5 minutes; immersed in varnish for the fifth time and placed on dust-free paper for 5 minutes; baked for the second time at a temperature of 130°C and a baking time of 3 hours;

[0045] (5) Wrap the primary enameled wire with a middle layer of high temperature resistant insulating tape, then wrap the secondary enameled wire around the middle layer of high temperature resistant insulating tape, and wrap the outer layer of high temperature resistant insulating tape around the secondary enameled wire. The secondary enameled wire winding starts from the right side of the air gap and winds in a clockwise direction until it reaches 2 / 3 of the way, thus obtaining a finished enameled wire magnetic ring.

[0046] (6) The finished enameled wire magnetic ring prepared in step (5) is immersed in varnish for the first time and placed on dust-free paper for 5 minutes; immersed in varnish for the second time and placed on dust-free paper for 5 minutes; immersed in varnish for the third time; baked for the first time at a baking temperature of 130°C and a baking time of 3 hours; immersed in varnish for the fourth time and placed on dust-free paper for 5 minutes; immersed in varnish for the fifth time and placed on dust-free paper for 5 minutes; baked for the second time at a baking temperature of 130°C and a baking time of 3 hours.

[0047] The present invention selects three-layer insulated wire as the enameled wire material, and the three-layer insulated wire can withstand a high voltage of 8000V. In addition, a multi-layer structure of high-temperature resistant insulating tape is arranged (inner layer, middle layer and outer layer high-temperature resistant insulating tape winding structure) to enhance the high-voltage resistance. After the wire package is wound, it is immersed in varnish for multiple times to enhance its high-voltage insulation resistance. The final product can reach a high voltage of 20000V.

[0048] The above description is only a specific implementation mode of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A pin-type high-power pulse transformer, characterized in that: The invention comprises a magnetic ring (1), an enameled wire (2), an inner layer of high temperature resistant insulating tape (3), a plastic base (4), a middle layer of high temperature resistant insulating tape (6) and an outer layer of high temperature resistant insulating tape (7), wherein the enameled wire (2) adopts three layers of insulating wire, including a primary enameled wire and a secondary enameled wire, the plastic base (4) has an opening at one end, and a PIN needle (5) is arranged on the open end of the plastic base (4), the outer surface of the magnetic ring (1) is wound with the inner layer of high temperature resistant insulating tape (3), the primary enameled wire is wound around the outer surface of the inner layer of high temperature resistant insulating tape (3), the middle layer of high temperature resistant insulating tape (6) and the outer layer of high temperature resistant insulating tape (7) are wound around the primary enameled wire, and the secondary enameled wire (7) is wound around the primary enameled wire. A layer of high temperature resistant insulating tape (6) is wound around the primary enameled wire, the secondary enameled wire is wound around the middle layer of high temperature resistant insulating tape (6), the outer layer of high temperature resistant insulating tape (7) is wound around the secondary enameled wire, the magnetic ring (1) formed by winding the enameled wire (2) constitutes a magnetic ring wire package of a semi-finished transformer, the magnetic ring wire package is placed in a plastic base (4) and is fully encapsulated and fixed with epoxy resin, the free end of the enameled wire (2) is electrically connected to the PIN needle (5); the magnetic ring (1) is a circular magnetic ring; the magnetic ring (1) is provided with an air gap (8).

2. A pin-type high-power pulse transformer according to claim 1, characterized in that: The inner layer of high temperature resistant insulating tape (3) and the outer layer of high temperature resistant insulating tape (7) are both wound in two layers, and the middle layer of high temperature resistant insulating tape (6) is wound in four layers. After the outer and inner layers between two adjacent layers are wound, the outer layer is wound around the gap between the inner layers.

3. A pin-type high-power pulse transformer according to claim 1, characterized in that: A mounting column (9) is provided in the middle of the plastic base (4), and the mounting column (9) is provided with a stepped through hole.

4. A pin-type high-power pulse transformer according to claim 1, characterized in that: Extension sections (10) are provided on both sides of the opening end of the plastic base (4), and grooves (11) are provided at the corners.

5. The pin-type high-power pulse transformer according to claim 1, characterized in that: A U-shaped groove (12) is provided at the location where the PIN pin (5) is provided on the plastic base (4), and the U-shaped groove (12) opens toward the inner side of the plastic base (4).

6. The pin-type high-power pulse transformer according to claim 1, characterized in that: The plastic base (4) at the PIN needle (5) is provided with a step (13), the step thickness is 3.5-4.5 mm, and the step height is 10-14 mm.

7. The pin-type high-power pulse transformer according to claim 1, characterized in that: The wall thickness of the plastic base (4) is more than 1 mm.

8. A method for preparing the pin-type high-power pulse transformer according to claim 1, characterized in that: The method comprises the following steps: (1) Wrap the inner layer of high-temperature resistant insulating tape on the magnetic ring: Start from the tape on the left side of the air gap, start winding the wire counterclockwise to the air gap, then wind it back clockwise, with the wire ends on the left; (2) The primary enameled wire of the three-layer insulated wire is wound around the inner layer of high-temperature resistant insulating tape. The enameled wire is threaded with a hook needle. The magnetic ring is fixed on the fixture, and the hook needle is used to pass through the magnetic ring and thread the wire back and forth in a clockwise direction. (3) The enameled wire magnetic ring prepared in step (2) is immersed in varnish for the first time and placed on dust-free paper for 5 minutes; immersed in varnish for the second time and placed on dust-free paper for 5 minutes; immersed in varnish for the third time; baked for the first time at a temperature of 130°C and a baking time of 3 hours; immersed in varnish for the fourth time and placed on dust-free paper for 5 minutes; immersed in varnish for the fifth time and placed on dust-free paper for 5 minutes; baked for the second time at a temperature of 130°C and a baking time of 3 hours; (5) Wrap the primary enameled wire with a middle layer of high temperature resistant insulating tape, then wrap the secondary enameled wire around the middle layer of high temperature resistant insulating tape, and wrap the outer layer of high temperature resistant insulating tape around the secondary enameled wire. The secondary enameled wire winding starts from the right side of the air gap and winds in a clockwise direction until it reaches 2 / 3 of the way, thus obtaining a finished enameled wire magnetic ring. (6) The finished enameled wire magnetic ring prepared in step (5) is immersed in varnish for the first time and placed on dust-free paper for 5 minutes; immersed in varnish for the second time and placed on dust-free paper for 5 minutes; immersed in varnish for the third time; baked for the first time at a baking temperature of 130°C and a baking time of 3 hours; immersed in varnish for the fourth time and placed on dust-free paper for 5 minutes; immersed in varnish for the fifth time and placed on dust-free paper for 5 minutes; baked for the second time at a baking temperature of 130°C and a baking time of 3 hours.

Images