Transformer with reduced ac losses for improved reliability and method of use

Abstract

This invention discloses a transformer and its usage method that reduce AC losses and improve reliability, belonging to the field of transformer technology. It integrates and isolates the primary, secondary, and resonant coils using an insulated support frame. The primary coil is wound in series within the slots of the insulated support frame, effectively reducing the high AC losses associated with parallel winding of the primary coil. The secondary copper sheets can be directly inserted into the insulated support frame, providing a fixed physical distance between the primary and secondary coils, effectively solving the problem of insufficient isolation in previous designs. The fixed physical isolation distance of the plastic body also effectively prevents the risk of high-voltage breakdown, resulting in good product consistency, simplified manufacturing processes, and ease of mass production. Power density is also increased, product size is smaller, energy utilization is significantly improved, and social resources are protected.

Description

Technical Field

[0001] This invention relates to a transformer, and more particularly to a transformer that reduces AC losses and improves reliability. The invention also relates to a method of using the transformer, and particularly to a transformer that reduces AC losses and improves reliability, and its method of use, belonging to the field of transformer technology. Background Technology

[0002] In the prior art, such as CN201810792055.9, an integrated transformer is described. The 220 primary winding and 210 secondary winding of this transformer generally use a stacked structure. The 220 primary winding and the 210 secondary winding are insulated from each other using a 300mm insulating film. The primary winding employs a multi-coil parallel stacking method, and the coils and the magnetic core are not physically isolated, as shown in the accompanying drawings. Figure 1 and Figure 2 As shown, the existing technology has the following problems:

[0003] a. Insufficient physical isolation distance between the primary and secondary sides of the transformer leads to a sharp increase in high-frequency AC losses due to voltage induction and the AC magnetic field of the primary / secondary sides.

[0004] b. Insufficient physical isolation distance between the primary and secondary sides and between the coil and the magnetic core poses a risk of high-voltage breakdown;

[0005] c. Parasitic parameters generated by series windings lead to higher high-frequency AC losses;

[0006] c. Complex structure, poor product consistency, and not easy to mass-produce;

[0007] d. High AC losses lead to larger product sizes to meet the requirements, resulting in low power density and a waste of social resources;

[0008] To address these issues, a transformer and its usage method were designed to reduce AC losses and improve reliability. Summary of the Invention

[0009] The main objective of this invention is to provide a transformer and its usage method that reduces AC losses and improves reliability. The primary, secondary, and resonant coils are integrated and isolated using an insulated support frame. The primary coil is wound in series within the slots of the insulated support frame, effectively reducing the high AC losses associated with parallel winding of the primary coil. The secondary copper sheets can be directly inserted into the insulated support frame, providing a fixed physical distance between the primary and secondary coils, effectively solving the problem of insufficient isolation in previous designs. The fixed physical isolation distance of the plastic body also effectively prevents the risk of high-voltage breakdown, resulting in good product consistency, simplified manufacturing processes, and ease of mass production. Power density is also increased, product size is smaller, energy efficiency is significantly improved, and social resources are protected. The primary coil is wound in series within the slots of the insulated support frame, with fixed relative positions and uniform distribution parameters, improving product consistency. The secondary copper sheets do not require insulation treatment; they are directly inserted into the insulated support frame for physical insulation, and their fixed relative positions and uniform distribution parameters further enhance product consistency.

[0010] The objective of this invention can be achieved by adopting the following technical solution:

[0011] A transformer with reduced AC losses and improved reliability includes a core frame assembly. A first insulating support frame group is provided at the upper inner part of the core frame assembly, on which a primary winding is wound. Secondary copper sheets are inserted into the core frame assembly at equal intervals. A second insulating support frame group is provided at the lower inner part of the core frame assembly, on which a resonant coil is wound. The primary winding extends from the first insulating support frame group through the side of the second insulating support frame group.

[0012] Preferably, the magnetic core frame assembly includes an upper magnetic core, a lower magnetic core, a middle magnetic core, a bottom insert, a middle insert, and an upper insert. A middle insert is installed in the middle of the middle magnetic core, and an upper magnetic core and a lower magnetic core are installed at the top and bottom of the middle magnetic core, respectively. A bottom insert penetrating the second insulating support frame assembly is provided at the middle of the inner bottom of the lower magnetic core. An upper insert penetrating the first insulating support frame assembly is provided at the middle of the bottom of the upper magnetic core. A middle insert penetrating below the first insulating support frame assembly is provided in the middle of the middle magnetic core, and the top of the middle insert is connected to the bottom of the upper insert, and the bottom of the middle insert is connected to the top of the bottom insert.

[0013] Preferably, the first insulating support frame group includes a first insulating support frame and a third insulating support frame, the first insulating support frame and the third insulating support frame are interlocked, the outer side of the first insulating support frame is wound with a primary side winding, and the inner side of the third insulating support frame is inserted with a secondary side copper sheet.

[0014] Preferably, the second insulating support frame group includes a second insulating support frame and an isolation limiting strip. The second insulating support frame is provided in multiple sets, and a resonant coil is wound around the outer side of the second insulating support frame. An isolation limiting strip is installed at the top edge of the second insulating support frame.

[0015] Preferably, both the third insulating support frame and the first insulating support frame are ring-shaped hollow structures, and one end of the ring structure extends outward to form an E-shaped frame structure.

[0016] Preferably, the second insulating support frame is also a ring-shaped hollow structure, and one end of the ring structure extends outward to form an E-shaped frame structure.

[0017] Preferably, both the first insulating support frame and the second insulating support frame have slots on one side for the primary winding to pass through.

[0018] The method for using a transformer that reduces AC losses and improves reliability includes the following steps:

[0019] The first and third insulating support frames are staggered to form a crenellation structure;

[0020] Insert the first insulating support frame and the third insulating support frame into the upper insert, and make the third insulating support frame fit against both sides of the upper magnetic core;

[0021] The primary winding is wound around the outside of the first insulating support frame and passed through the slot, and a secondary copper sheet is inserted into the third insulating support frame.

[0022] The second insulating support frame is set up and the resonant coil is wound around it.

[0023] Beneficial technical effects of the present invention:

[0024] This invention provides a transformer and its usage method that reduce AC losses and improve reliability. The primary, secondary, and resonant coils are integrated and isolated using an insulated support frame. The primary coil is wound in series within the slots of the insulated support frame, effectively reducing the high AC losses associated with parallel winding of the primary coil. The secondary copper sheets can be directly inserted into the insulated support frame, providing a fixed physical distance between the primary and secondary coils, effectively solving the problem of insufficient isolation in previous designs. The fixed physical isolation distance of the plastic body also effectively prevents the risk of high-voltage breakdown, resulting in good product consistency, simplified manufacturing processes, and ease of mass production. Power density is also increased, product size is smaller, energy utilization is significantly improved, and social resources are protected. The primary coil is wound in series within the slots of the insulated support frame, with fixed relative positions and uniform distribution parameters, improving product consistency. The secondary copper sheets do not require insulation treatment; they are directly inserted into the insulated support frame for physical insulation, and their fixed relative positions and uniform distribution parameters further enhance product consistency. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the three-dimensional structure of the existing technology;

[0026] Figure 2 This is a schematic diagram of the existing three-dimensional structure;

[0027] Figure 3 This is a first-view perspective three-dimensional structural diagram of a preferred embodiment of a transformer according to the present invention, which has reduced AC losses and improved reliability;

[0028] Figure 4 This is a second-view perspective three-dimensional structural diagram of a preferred embodiment of a transformer according to the present invention, which has reduced AC losses and improved reliability;

[0029] Figure 5 A diagram showing a preferred embodiment of the transformer according to the present invention, which has reduced AC losses and improved reliability;

[0030] Figure 6 This is a power-on test diagram of a preferred embodiment of the transformer according to the present invention, which has reduced AC losses and improved reliability.

[0031] In the diagram: 1-Upper magnetic core, 2-First insulating support frame, 3-Secondary copper sheet, 4-Primary winding, 5-Second insulating support frame, 6-Resonant coil, 7-Middle magnetic core, 8-Lower magnetic core, 9-Upper insert, 10-Slot, 11-Middle insert, 12-Bottom insert, 13-Isolation limit strip, 14-Third insulating support frame. Detailed Implementation

[0032] To enable those skilled in the art to understand the technical solution of the present invention more clearly, the present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the embodiments of the present invention are not limited thereto.

[0033] like Figures 3-4 As shown, the transformer provided in this embodiment, which reduces AC losses and improves reliability, includes a core frame assembly. A first insulating support skeleton group is provided at the upper part of the core frame assembly. A primary winding 4 is wound on the insulating support skeleton group, and secondary copper sheets 3 are inserted into the core frame assembly at equal intervals. A second insulating support skeleton group is provided at the lower part of the core frame assembly. A resonant coil 6 is wound on the inner side of the second insulating support skeleton group. The primary winding 4 extends from the first insulating support skeleton group through the side of the second insulating support skeleton group.

[0034] This invention integrates and isolates the primary, secondary, and resonant coils using an insulated support frame. The primary coil is wound in series within the slots of the insulated support frame, effectively reducing the high AC losses associated with parallel winding of the primary coil. The secondary copper sheets can be directly inserted into the insulated support frame, providing a fixed physical distance between the primary and secondary coils, effectively addressing the previous insufficient isolation. The fixed physical isolation distance of the plastic body also effectively prevents the risk of high-voltage breakdown, resulting in good product consistency, simplified manufacturing processes, and ease of mass production. Power density is also increased, product size is smaller, energy efficiency is significantly improved, and social resources are protected. The primary coil is wound in series within the slots of the insulated support frame, with fixed relative positions and uniform distribution parameters, enhancing product consistency. The secondary copper sheets do not require insulation treatment; they are directly inserted into the insulated support frame for physical insulation, and their fixed relative positions and uniform distribution parameters further improve product consistency.

[0035] In this embodiment, the magnetic core frame assembly includes an upper magnetic core 1, a lower magnetic core 8, a middle magnetic core 7, a bottom insert 12, a middle insert 11, and an upper insert 9. The middle insert 11 is installed in the middle of the middle magnetic core 7, and the upper magnetic core 1 and the lower magnetic core 8 are installed at the top and bottom of the middle magnetic core 7, respectively. The bottom insert 12, which penetrates the second insulating support frame assembly, is provided in the middle of the inner bottom of the lower magnetic core 8. The upper insert 9, which penetrates the first insulating support frame assembly, is provided in the middle of the bottom of the upper magnetic core 1. The middle insert 11, which penetrates the lower part of the first insulating support frame assembly, is provided in the middle of the middle magnetic core 7. The top of the middle insert 11 is connected to the bottom of the upper insert 9, and the bottom of the middle insert 11 is connected to the top of the bottom insert 12.

[0036] In this embodiment, the first insulating support frame group includes a first insulating support frame 2 and a third insulating support frame 14. The first insulating support frame 2 and the third insulating support frame 14 are interlocked and stacked. The outer side of the first insulating support frame 2 is wound with a primary side winding 4, and the inner side of the third insulating support frame 14 is inserted with a secondary side copper sheet 3.

[0037] In this embodiment, the second insulating support frame group includes a second insulating support frame 5 and an isolation limiting strip 13. Multiple sets of the second insulating support frame 5 are provided, and a resonant coil 6 is wound around the outer side of the second insulating support frame 5. An isolation limiting strip 13 is installed at the top edge of the second insulating support frame 5.

[0038] In this embodiment, both the third insulating support frame 14 and the first insulating support frame 2 are ring-shaped hollow structures, and one end of the ring structure extends outward to form an E-shaped frame structure.

[0039] In this embodiment, the second insulating support frame 5 is also a ring-shaped hollow structure, and one end of the ring structure extends outward to form an E-shaped frame structure.

[0040] In this embodiment, both the first insulating support frame 2 and the second insulating support frame 5 have slots 10 on one side for the primary winding 4 to pass through.

[0041] The method for using a transformer that reduces AC losses and improves reliability includes the following steps:

[0042] The first insulating support frame 2 and the third insulating support frame 14 are staggered to form a crenellation structure;

[0043] Insert the first insulating support frame 2 and the third insulating support frame 14 into the upper insert 9, and make the third insulating support frame 14 fit against both sides of the upper magnetic core 1.

[0044] The primary winding 4 is wound around the outside of the first insulating support frame 2 and passed through the slot 10, and a secondary copper sheet 3 is inserted into the third insulating support frame 14.

[0045] The second insulating support frame 5 is set up and the resonant coil 6 is wound around it.

[0046] In this embodiment, the following is true: Figure 5 As shown, under the same conditions, the proximity effect loss ratio of the series winding with added insulation support frame under high-frequency interference is 0.0625 / 0.315, while the proximity effect loss ratio of the conventional thin-film isolated parallel winding under high-frequency interference is 0.5 / 2.5. The calculated AC loss of the series winding with added insulation support frame is 333 / 1499 mW, while the calculated AC loss of the conventional thin-film isolated parallel winding is 2665 / 12060 mW. The conclusion is that the loss of the series winding with added insulation support frame is much smaller than that of the conventional thin-film isolated parallel winding. The final calculated temperature is 90℃ compared to 122℃.

[0047] The above theoretical results were verified through actual electrical testing, and the results are as follows: Figure 6As shown in the figure, the temperature of the series winding after adding the insulating support frame is 87℃, and the temperature of the conventional thin-film isolated parallel winding is 121℃. The results show that the measured temperature is very close to the theoretical calculation value. Therefore, the invention of this patent can effectively reduce high-frequency AC loss.

[0048] The above are merely further embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope disclosed in the present invention, based on the technical solution and concept of the present invention, shall fall within the scope of protection of the present invention.

Claims

1. A transformer having reduced AC losses and improved reliability, characterized by: The magnetic core frame assembly includes a first insulating support frame group located at the upper inner part of the magnetic core frame assembly. A primary winding (4) is wound on the insulating support frame group, and secondary copper sheets (3) are inserted into the magnetic core frame assembly at equal intervals. A second insulating support frame group is located at the lower inner part of the magnetic core frame assembly. A resonant coil (6) is wound on the outer side of the second insulating support frame group. The primary winding (4) extends from the first insulating support frame group through the side of the second insulating support frame group. The first insulating support frame group includes a first insulating support frame (2) and a third insulating support frame (14). The first insulating support frame (2) and the third insulating support frame (14) are interlocked. The outer side of the first insulating support frame (2) is wound with a primary side winding (4), and the inner side of the third insulating support frame (14) is inserted with a secondary side copper sheet (3). The second insulating support frame group includes a second insulating support frame (5) and an isolation limiting strip (13). The second insulating support frame (5) is provided with multiple sets, and a resonant coil (6) is wound around the outside of the second insulating support frame (5). An isolation limiting strip (13) is installed at the top edge of the second insulating support frame (5).

2. The transformer with reduced AC losses and improved reliability according to claim 1, characterized in that: The magnetic core frame assembly includes an upper magnetic core (1), a lower magnetic core (8), a middle magnetic core (7), a bottom insert (12), a middle insert (11), and an upper insert (9). The middle insert (11) is installed in the middle of the middle magnetic core (7), and the upper magnetic core (1) and the lower magnetic core (8) are installed at the top and bottom of the middle magnetic core (7), respectively. The bottom insert (12) penetrating the second insulating support frame group is provided at the middle of the inner bottom of the lower magnetic core (8). The upper insert (9) penetrating the first insulating support frame group is provided at the middle of the bottom of the upper magnetic core (1). The middle insert (11) penetrating the bottom of the first insulating support frame group is provided at the middle of the middle of the middle magnetic core (7). The top of the middle insert (11) is connected to the bottom of the upper insert (9), and the bottom of the middle insert (11) is connected to the top of the bottom insert (12).

3. The transformer with reduced AC losses and improved reliability according to claim 2, characterized in that: The third insulating support frame (14) and the first insulating support frame (2) are both annular hollow structures, and one end of the annular structure extends outward to form an E-shaped frame structure.

4. The transformer with reduced AC losses and improved reliability according to claim 3, characterized in that: The second insulating support frame (5) is also a ring-shaped hollow structure, and one end of the ring structure extends outward to form an E-shaped frame structure.

5. The transformer with reduced AC losses and improved reliability according to claim 4, characterized in that: Both the first insulating support frame (2) and the second insulating support frame (5) have slots (10) on one side for the primary winding (4) to pass through.

6. The method of using a transformer with reduced ac losses and improved reliability according to claim 5, wherein: Includes the following steps: The first insulating support frame (2) and the third insulating support frame (14) are staggered to form a crenellation structure; Insert the first insulating support frame (2) and the third insulating support frame (14) into the upper insert (9) and make the third insulating support frame (14) fit against both sides of the upper magnetic core (1); The primary winding (4) is wound around the outside of the first insulating support frame (2) and passed through the slot (10), and a secondary copper sheet (3) is inserted into the third insulating support frame (14). The second insulating support frame (5) is stacked and the resonant coil (6) is wound around it.

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