Horizontal Transformer and its Manufacturing Method

Abstract

This invention relates to a horizontal transformer and its manufacturing method. The winding includes a coil winding and a conductor foil winding. The conductor foil winding includes a first conductor foil and a second conductor foil stacked in a staggered manner. The outer peripheral surfaces of both the first and second conductor foils are wound with a second insulating layer, and both ends of the first and second conductor foils extend beyond the second insulating layer. The two ends of the first and second conductor foils respectively have a first welded portion and a second welded portion. This improves efficiency, reduces magnetic loss, and facilitates direct heat dissipation, thereby improving heat dissipation efficiency.

Description

Technical Field

[0001] This invention relates to the field of horizontal transformer technology, and in particular to horizontal transformers and their manufacturing methods. Background Technology

[0002] like Figures 1 to 4 As shown, existing LLC transformers are generally frameless wound transformers, which include an upper magnetic core 11, a lower magnetic core 12, a copper tin plate, a vertical plate 13, a base plate 14, and windings.

[0003] The upper magnetic core 11 and the lower magnetic core 12 are arranged vertically opposite each other and connected. The vertical plate 13 and the bottom plate 14 form an L-shaped structure. The vertical plate 13 is located behind both the upper magnetic core 11 and the lower magnetic core 12. Both the upper magnetic core 11 and the lower magnetic core 12 are located above the bottom plate 14.

[0004] The copper tin-plated plates are arranged in three vertically spaced sections behind the vertical plate 13. The lower end of each copper tin-plated plate passes through the bottom plate 14 and extends beyond the lower end surface of the bottom plate 14 to form the secondary winding pull end. From right to left, they are pull end C, pull end D and pull end E respectively.

[0005] The winding includes, from top to bottom, a first insulating pad, an N7 coil, a second insulating pad, an N6 coil, a third insulating pad, an N5 coil, a fourth insulating pad, an N4 coil, a fifth insulating pad, an N3 coil, a sixth insulating pad, an N2 coil, a seventh insulating pad, an N1 coil, and an eighth insulating pad; wherein, the N2 coil, N4 coil, and N6 coil are all coils and together form the primary winding. The primary winding has a draw-out end A and a draw-out end B. The two ends of the N2 coil, N4 coil, and N6 coil pass through the base plate 14 and are welded to the draw-out end A and the draw-out end B, respectively.

[0006] The N7, N5, N3, and N1 coils form the secondary winding. All four coils are flat coils, each with a first lead end and a second lead end.

[0007] like Figure 2 As shown, the three copper tin-plated plates are defined from left to right as the first copper tin-plated plate 151, the second copper tin-plated plate 152, and the third copper tin-plated plate 153. The height of the three copper tin-plated plates 151, 152, and 153 gradually increases from right to left.

[0008] The first leads of both the N7 and N5 coils pass through the vertical plate 13 and the first copper tin plate 151 in sequence, and then extend out of the first copper tin plate 151. The first leads of both the N7 and N5 coils are soldered to the first copper tin plate 151. The second leads of both the N7 and N5 coils pass through the vertical plate 13 and the second copper tin plate 152 in sequence, and then extend out of the second copper tin plate 152. The second leads of both the N7 and N5 coils are soldered to the second copper tin plate 152.

[0009] The first leads of both the N3 and N1 coils pass through the vertical plate 13 and the second copper-plated tin plate 152 in sequence, and then extend out of the second copper-plated tin plate 152. The first leads of both the N3 and N1 coils are soldered to the second copper-plated tin plate 152. The second leads of both the N3 and N1 coils pass through the vertical plate 13 and the third copper-plated tin plate 153 in sequence, and then extend out of the third copper-plated tin plate 153. The second leads of both the N3 and N1 coils are soldered to the third copper-plated tin plate 153.

[0010] However, the above-mentioned transformer has the following structural defects:

[0011] 1. Flat coils require mold making;

[0012] 2. The N7, N5, N3 and N1 coils need to be connected in parallel and then soldered to the corresponding copper-plated tin plates. In the event of a large current, the presence of the copper-plated tin plates will cause losses, which will lead to a decrease in efficiency. In addition, the entire process is costly.

[0013] Therefore, in this patent application, the applicant has carefully studied horizontal transformers and their manufacturing methods to solve the above-mentioned problems. Summary of the Invention

[0014] The present invention addresses the shortcomings of the prior art by providing a horizontal transformer and its manufacturing method, which improves efficiency, reduces magnetic losses, and facilitates direct heat dissipation, thereby improving heat dissipation efficiency.

[0015] To achieve the above objectives, the present invention adopts the following technical solution:

[0016] A horizontal transformer includes a frame, a first magnetic core, a second magnetic core, and a winding; the frame has a winding shaft, the first magnetic core is disposed in front of the frame and partially embedded in the frame, the second magnetic core is opposite to the first magnetic core and disposed behind the frame and partially embedded in the frame, and the winding is wound on the winding shaft and surrounds the first magnetic core and the portion of the second magnetic core embedded in the frame.

[0017] The winding includes a coil winding and a conductor foil winding. The coil winding is wound on a winding shaft and surrounds the portion of the first magnetic core and the second magnetic core embedded in the main body. The coil winding has a first lead end and a second lead end, both of which extend out of the skeleton. The outer peripheral surface of the coil winding is wrapped with a first insulating layer.

[0018] The conductor foil winding is wound on the first insulating layer. The conductor foil winding includes a first conductor foil and a second conductor foil stacked in a staggered manner. The outer peripheral surfaces of both the first conductor foil and the second conductor foil are wound with the second insulating layer, and both ends of both extend beyond the second insulating layer. The two ends of the first conductor foil and the second conductor foil respectively have a first welding part and a second welding part.

[0019] Both the first conductor foil and the second conductor foil are bendable Z-shaped conductor foils. The Z-shaped conductor foil includes a longitudinal portion, a first transverse portion and a second transverse portion. The two ends of the first transverse portion are respectively connected to the longitudinal portion and the first welding portion, and the two ends of the second transverse portion are respectively connected to the longitudinal portion and the second welding portion.

[0020] The first transverse portion of the first conductor foil is simultaneously stacked on top of the front portion of the longitudinal portion of the second conductor foil and a portion of the first transverse portion, and the first weld portion of the first conductor foil is located inside the first weld portion of the second conductor foil;

[0021] The second transverse portion of the second conductor foil is simultaneously stacked on top of the rear portion of the longitudinal portion of the first conductor foil and a portion of the second transverse portion, and the second weld portion of the first conductor foil is located outside the second weld portion of the second conductor foil;

[0022] The first transverse portion of the first conductor foil, the front portion of the longitudinal portion of the second conductor foil, and the first transverse portion are wound together in one direction on the outer periphery of a portion of the first insulating layer;

[0023] The second transverse portion of the second conductor foil, the rear portion of the longitudinal portion of the first conductor foil, and the second transverse portion are wound together in another direction around the outer periphery of another portion of the first insulating layer.

[0024] As a preferred embodiment, the first conductor foil and the second conductor foil have identical structures.

[0025] As a preferred embodiment, the circuit board is also included, wherein the first lead end, the second lead, and the first and second solder joints of the first conductor foil and the second conductor foil are all soldered to the circuit board and all extend out of the same end face of the circuit board.

[0026] As a preferred embodiment, the device also includes a core-wrapping tape, which wraps around the first and second magnetic cores.

[0027] A method for manufacturing a horizontal transformer, comprising the following steps:

[0028] S1. First, prepare the skeleton, first magnetic core, second magnetic core, winding, first insulating layer, and second insulating layer; the skeleton has a winding shaft, the winding includes a coil winding and a conductor foil winding, the coil winding has a first lead end and a second lead end, the conductor foil winding includes a first conductor foil and a second conductor foil, the two ends of the first conductor foil and the second conductor foil respectively have a first welding part and a second welding part, the first conductor foil and the second conductor foil are both bendable Z-shaped conductor foils, the Z-shaped conductor foil includes a longitudinal part, a first transverse part and a second transverse part, the two ends of the first transverse part are respectively connected to the longitudinal part and the first welding part, the two ends of the second transverse part are respectively connected to the longitudinal part and the second welding part.

[0029] S2. The winding wires of the coil winding are wound layer by layer on the winding shaft to form the N1 coil, and the first lead end and the second lead end are both extended outside the skeleton;

[0030] S3. The first insulating layer is wound around the outer peripheral surface of the wire winding;

[0031] S4. A second insulating layer is wound around the outer peripheral surfaces of both the first conductor foil and the second conductor foil, with both ends of both extending beyond the second insulating layer. The first weld portion and the second weld portion of the first conductor foil and the second conductor foil both extend beyond the second insulating layer.

[0032] S5. The first conductor foil and the second conductor foil are stacked in a staggered manner, with the first transverse portion of the first conductor foil stacked above the front portion of the longitudinal portion of the second conductor foil and part of the first transverse portion, and the first welding portion of the first conductor foil located inside the first welding portion of the second conductor foil.

[0033] The second transverse portion of the second conductor foil is simultaneously stacked on top of the rear portion of the longitudinal portion of the first conductor foil and a portion of the second transverse portion, and the second weld portion of the first conductor foil is located outside the second weld portion of the second conductor foil;

[0034] S6. The first transverse portion of the first conductor foil, the front portion of the longitudinal portion of the second conductor foil, and the first transverse portion are wound together in one direction on the outer periphery of a portion of the first insulating layer to form an N2 loop.

[0035] The second transverse portion of the second conductor foil, the rear portion of the longitudinal portion of the first conductor foil, and the second transverse portion are wound together in another direction on the outer periphery of another portion of the first insulating layer, thus completing the conductor foil winding on the first insulating layer;

[0036] S7. First, place the first magnetic core in front of the frame and partially embed it in the frame. Then, place the second magnetic core opposite the first magnetic core, place the second magnetic core behind the frame and partially embed it in the frame, and let the winding surround the first magnetic core and the part of the second magnetic core embedded in the frame.

[0037] As a preferred embodiment, in step S1, a circuit board is also prepared;

[0038] It also includes the following steps:

[0039] S8. Solder the first lead end, the second lead, and the first and second soldering parts of both the first conductor foil and the second conductor foil to the circuit board, and all of them extend out of the same end face of the circuit board.

[0040] As a preferred option, in step S1, a magnetic core wrapping tape is also prepared;

[0041] It also includes the following steps:

[0042] S9. Wrap the first and second magnetic cores with core-wrapping tape.

[0043] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, it mainly improves the secondary winding by staggering the first conductor foil and the second conductor foil, thereby improving efficiency and reducing magnetic loss. Moreover, the first conductor foil and the second conductor foil facilitate direct heat dissipation and improve heat dissipation efficiency. Attached Figure Description

[0044] Figure 1 This is a side view of the prior art;

[0045] Figure 2 This is a rear view of the prior art;

[0046] Figure 3 This is a schematic diagram of a coil from existing technology;

[0047] Figure 4 This is a top-view exploded structural diagram of an embodiment of the present invention; (the first insulating layer and the second insulating layer are not shown).

[0048] Figure 5 This is a cross-sectional structural schematic diagram of an embodiment of the present invention;

[0049] Figure 6 This is a schematic diagram of the first conductor foil and the second conductor foil in an unstacked state according to an embodiment of the present invention;

[0050] Figure 7 This is a schematic diagram of the first conductor foil and the second conductor foil in a stacked state according to an embodiment of the present invention.

[0051] Explanation of icon numbers:

[0052] 11. Upper magnetic core 12. Lower magnetic core

[0053] 13. Vertical plate 14. Base plate

[0054] 151. First copper tin-plated plate

[0055] 152. Second copper tin-plated plate

[0056] 153. Third type of copper tinplate

[0057] 21. Skeleton 211. Winding bobbin

[0058] 22. First magnetic core; 23. Second magnetic core; 24. Circuit board

[0059] 31. Coil winding; 32. First insulation layer

[0060] 401. First conductor foil; 402. Second conductor foil

[0061] 403. First welding section; 404. Second welding section

[0062] 41. First transverse section

[0063] 42. Longitudinal section 43. Second transverse section

[0064] 44. Second insulation layer. Detailed Implementation

[0065] The present invention will now be further described with reference to the accompanying drawings and specific embodiments.

[0066] like Figures 4 to 7 As shown, a horizontal transformer includes a frame 21, a first magnetic core 22, a second magnetic core 23, windings, a circuit board 24, and core-wrapping tape.

[0067] The frame 21 has a winding shaft. Preferably, the first magnetic core 22 and the second magnetic core 23 are iron cores. The first magnetic core 22 is located in front of the frame 21 and partially embedded in the frame 21. The second magnetic core 23 is directly opposite the first magnetic core 22 and is located behind the frame 21 and partially embedded in the frame 21. The core-wrapping tape wraps the first magnetic core 22 and the second magnetic core 23 to form the frame 21, the winding, the first magnetic core 22, and the second magnetic core 23 into a whole.

[0068] The winding is wound on a winding shaft and surrounds the portion of the first magnetic core 22 and the second magnetic core 23 embedded in the frame 21.

[0069] The winding includes a coil winding 31 and a conductor foil winding. The coil winding 31 is wound on a winding shaft and surrounds the portion of the first magnetic core 22 and the second magnetic core 23 embedded in the main body. The coil winding 31 has a first lead end and a second lead end, both of which extend out of the skeleton 21. The outer peripheral surface of the coil winding 31 is wrapped with a first insulating layer 32.

[0070] The conductor foil winding is wound on the first insulating layer 32, and the conductor foil winding includes a first conductor foil 401 and a second conductor foil 402 stacked in a staggered manner. Preferably, the first conductor foil 401 and the second conductor foil 402 have the same structure.

[0071] In this embodiment, both the first conductor foil 401 and the second conductor foil 402 are made of copper foil because copper foil has good conductivity. Preferably, the copper foil is made of red copper. In actual operation, aluminum foil or other materials with good conductivity can also be used to make the conductor foil, depending on actual needs; this is not limited here. In addition, the thickness of the first conductor foil 401 and the second conductor foil 402 needs to be selected according to the magnitude of the load current.

[0072] Both the first conductor foil 401 and the second conductor foil 402 have a second insulating layer 44 wound around their outer peripheral surfaces, and both ends of the first conductor foil 401 and the second conductor foil 402 extend beyond the second insulating layer 44. In this embodiment, both the first insulating layer 32 and the second insulating layer 44 are insulating tape layers. The first conductor foil 401 and the second conductor foil 402 have a first welding portion 403 and a second welding portion 404 at their respective ends.

[0073] The first lead end, the second lead, and the first welding portion 403 and the second welding portion 404 of the first conductor foil 401 and the second conductor foil 402 are all welded to the circuit board 24 and all extend out of the same end face of the circuit board 24.

[0074] The first conductor foil 401 and the second conductor foil 402 are both bendable Z-shaped conductor foils. The Z-shaped conductor foil includes a longitudinal portion 42, a first transverse portion 41 and a second transverse portion 43. The two ends of the first transverse portion 41 are respectively connected to the longitudinal portion 42 and the first welding portion 403, and the two ends of the second transverse portion 43 are respectively connected to the longitudinal portion 42 and the second welding portion 404.

[0075] The first transverse portion 41 of the first conductor foil 401 is simultaneously stacked on the front portion of the longitudinal portion 42 of the second conductor foil 402 and on top of part of the first transverse portion 41. The first welding portion 403 of the first conductor foil 401 is located inside the first welding portion 403 of the second conductor foil 402.

[0076] The second transverse portion 43 of the second conductor foil 402 is simultaneously stacked above the rear portion of the longitudinal portion 42 of the first conductor foil 401 and above a portion of the second transverse portion 43, and the second solder portion 404 of the first conductor foil 401 is located outside the second solder portion 404 of the second conductor foil 402.

[0077] The first transverse portion 41 of the first conductor foil 401, the front portion of the longitudinal portion 42 of the second conductor foil 402, and the first transverse portion 41 are wound together in one direction on the outer periphery of a portion of the first insulating layer 32.

[0078] The second transverse portion 43 of the second conductor foil 402, the rear portion of the longitudinal portion 42 of the first conductor foil 401, and the second transverse portion 43 are wound together in another direction around the outer periphery of another portion of the first insulating layer 32.

[0079] A method for manufacturing a horizontal transformer, comprising the following steps:

[0080] S1. First, prepare the frame 21, the first magnetic core 22, the second magnetic core 23, the winding, the first insulating layer 32, the second insulating layer 44, the circuit board 24, and the magnetic core wrapping tape.

[0081] The skeleton 21 has a winding shaft, and the winding includes a coil winding 31 and a conductor foil winding. The coil winding 31 has a first lead end and a second lead end. The conductor foil winding includes a first conductor foil 401 and a second conductor foil 402. The first conductor foil 401 and the second conductor foil 402 have a first welding part 403 and a second welding part 404 at their respective ends. The first conductor foil 401 and the second conductor foil 402 are both bendable Z-shaped conductor foils. The Z-shaped conductor foil includes a longitudinal part 42 and a first transverse part 41 and a second transverse part 43 integrally connected to the longitudinal part 42.

[0082] S2. The winding wires of the coil winding 31 are wound layer by layer on the winding shaft to form the N1 coil, and the first lead end and the second lead end both extend out of the skeleton 21.

[0083] S3. The first insulating layer 32 is wound around the outer peripheral surface of the coil winding 31;

[0084] S4. The outer peripheral surfaces of both the first conductor foil 401 and the second conductor foil 402 are wrapped with a second insulating layer 44, and both ends of both extend out of the second insulating layer 44. The first welding part 403 and the second welding part 404 of the first conductor foil 401 and the second conductor foil 402 extend out of the second insulating layer 44.

[0085] S5. The first conductor foil 401 and the second conductor foil 402 are stacked in a staggered manner. The first transverse portion 41 of the first conductor foil 401 is simultaneously stacked on top of the front part of the longitudinal portion 42 of the second conductor foil 402 and part of the first transverse portion 41. The first welding portion 403 of the first conductor foil 401 is located inside the first welding portion 403 of the second conductor foil 402.

[0086] The second transverse portion 43 of the second conductor foil 402 is simultaneously stacked above the rear portion of the longitudinal portion 42 of the first conductor foil 401 and above a portion of the second transverse portion 43, and the second solder portion 404 of the first conductor foil 401 is located outside the second solder portion 404 of the second conductor foil 402.

[0087] S6. The first transverse portion 41 of the first conductor foil 401, the front part of the longitudinal portion 42 of the second conductor foil 402, and the first transverse portion 41 are wound together in one direction on the outer periphery of a portion of the first insulating layer 32 to form an N2 loop.

[0088] The second transverse portion 43 of the second conductor foil 402, the rear portion of the longitudinal portion 42 of the first conductor foil 401, and the second transverse portion 43 are wound together in another direction on the outer periphery of another part of the first insulating layer 32, thus completing the conductor foil winding on the first insulating layer 32.

[0089] S7. First, place the first magnetic core 22 in front of the frame 21 and partially embed it in the frame 21. Then, place the second magnetic core 23 opposite to the first magnetic core 22, place the second magnetic core 23 behind the frame 21 and partially embed it in the frame 21, and let the winding surround the first magnetic core 22 and the part of the second magnetic core 23 embedded in the frame 21.

[0090] S8. The first welding part 403 and the second welding part 404 of the first lead end, the second lead, the first conductor foil 401 and the second conductor foil 402 are all welded to the circuit board 24, and all of them extend out of the same end face of the circuit board 24.

[0091] S9. Wrap the first magnetic core 22 and the second magnetic core 23 with magnetic core wrapping tape.

[0092] It should be noted that the number of turns of the horizontal transformer obtained by the above manufacturing method is as follows:

[0093] The ratio of N1:N2:N3 is 28:2:2, instead of the traditional 14:1:1. This design ensures that the number of primary turns in the horizontal transformer is sufficient, resulting in a large inductance, low magnetic loss, and reduced saturation. Consequently, the inductance value is easier to determine, leading to a more rational design.

[0094] In this embodiment, the first lead end, the second lead, and the first welding part 403 and the second welding part 404 of the first conductor foil 401 and the second conductor foil 402 can be directly welded to the PCB, which reduces conduction loss and further improves efficiency in high current applications.

[0095] In this embodiment, after installation with the computer motherboard, because the horizontal transformer adopts a horizontal design, its first conductor foil 401 and second conductor foil 402 are exposed. Therefore, when the fan on the motherboard blows directly on it, it is beneficial for heat dissipation. Moreover, the first conductor foil 401 and second conductor foil 402 can withstand a larger current. Therefore, the same volume of magnetic core can produce greater power and save money.

[0096] The key design features of this invention are: it mainly improves the secondary winding by staggering the first and second conductor foils to increase efficiency and reduce magnetic loss. Furthermore, the first and second conductor foils facilitate direct heat dissipation, thereby improving heat dissipation efficiency.

[0097] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A horizontal transformer, comprising a frame, a first magnetic core, a second magnetic core, and a winding; the frame has a winding shaft, the first magnetic core is disposed in front of the frame and partially embedded in the frame, the second magnetic core is opposite to the first magnetic core and disposed behind the frame and partially embedded in the frame, the winding is wound on the winding shaft and surrounds the portions of the first and second magnetic cores embedded in the frame, characterized in that: The winding includes a coil winding and a conductor foil winding. The coil winding is wound on a winding shaft and surrounds the portion of the first magnetic core and the second magnetic core embedded in the main body. The coil winding has a first lead end and a second lead end, both of which extend out of the skeleton. The outer peripheral surface of the coil winding is wrapped with a first insulating layer. The conductor foil winding is wound on the first insulating layer. The conductor foil winding includes a first conductor foil and a second conductor foil stacked in a staggered manner. The outer peripheral surfaces of both the first conductor foil and the second conductor foil are wound with the second insulating layer, and both ends of both extend beyond the second insulating layer. The two ends of the first conductor foil and the second conductor foil respectively have a first welding part and a second welding part. Both the first conductor foil and the second conductor foil are bendable Z-shaped conductor foils. The Z-shaped conductor foil includes a longitudinal portion, a first transverse portion and a second transverse portion. The two ends of the first transverse portion are respectively connected to the longitudinal portion and the first welding portion, and the two ends of the second transverse portion are respectively connected to the longitudinal portion and the second welding portion. The first transverse portion of the first conductor foil is simultaneously stacked on top of the front portion of the longitudinal portion of the second conductor foil and a portion of the first transverse portion, and the first weld portion of the first conductor foil is located inside the first weld portion of the second conductor foil; The second transverse portion of the second conductor foil is simultaneously stacked on top of the rear portion of the longitudinal portion of the first conductor foil and a portion of the second transverse portion, and the second weld portion of the first conductor foil is located outside the second weld portion of the second conductor foil; The first transverse portion of the first conductor foil, the front portion of the longitudinal portion of the second conductor foil, and the first transverse portion are wound together in one direction on the outer periphery of a portion of the first insulating layer; The second transverse portion of the second conductor foil, the rear portion of the longitudinal portion of the first conductor foil, and the second transverse portion are wound together in another direction around the outer periphery of another portion of the first insulating layer.

2. The horizontal transformer according to claim 1, characterized in that: The first conductor foil and the second conductor foil have the same structure.

3. The horizontal transformer according to claim 1, characterized in that: It also includes a circuit board, wherein the first lead end, the second lead end, and the first and second welding portions of the first conductor foil and the second conductor foil are all welded to the circuit board and all extend out of the same end face of the circuit board.

4. The horizontal transformer according to claim 1, characterized in that: It also includes core-wrapping tape, which wraps around the first and second magnetic cores.

5. A method for manufacturing a horizontal transformer, characterized in that: Its use in manufacturing the horizontal transformer according to any one of claims 1 to 4 includes the following steps: S1. First, prepare a skeleton, a first magnetic core, a second magnetic core, a winding, a first insulating layer, and a second insulating layer; the skeleton has a winding shaft, the winding includes a coil winding and a conductor foil winding, the coil winding has a first lead end and a second lead end, the conductor foil winding includes a first conductor foil and a second conductor foil, the two ends of the first conductor foil and the second conductor foil respectively have a first welding part and a second welding part, the first conductor foil and the second conductor foil are both bendable Z-shaped conductor foils, the Z-shaped conductor foil includes a longitudinal part, a first transverse part and a second transverse part, the two ends of the first transverse part are respectively connected to the longitudinal part and the first welding part, and the two ends of the second transverse part are respectively connected to the longitudinal part and the second welding part; S2. The winding wires of the coil winding are wound layer by layer on the winding shaft to form the N1 coil, and the first lead end and the second lead end are both extended outside the skeleton; S3. Wrap the first insulating layer around the outer peripheral surface of the wire winding; S4. Wrap the outer peripheral surfaces of both the first conductor foil and the second conductor foil with the second insulating layer, with both ends of both extending beyond the second insulating layer. The first weld portion and the second weld portion of the first conductor foil and the second conductor foil both extend beyond the second insulating layer. S5. The first conductor foil and the second conductor foil are stacked in a staggered manner, with the first transverse portion of the first conductor foil stacked above the front portion of the longitudinal portion of the second conductor foil and part of the first transverse portion, and the first welding portion of the first conductor foil located inside the first welding portion of the second conductor foil. The second transverse portion of the second conductor foil is simultaneously stacked on top of the rear portion of the longitudinal portion of the first conductor foil and a portion of the second transverse portion, and the second weld portion of the first conductor foil is located outside the second weld portion of the second conductor foil; S6. The first transverse portion of the first conductor foil, the front portion of the longitudinal portion of the second conductor foil, and the first transverse portion are wound together in one direction on the outer periphery of a portion of the first insulating layer to form an N2 loop. The second transverse portion of the second conductor foil, the rear portion of the longitudinal portion of the first conductor foil, and the second transverse portion are wound together in another direction on the outer periphery of another portion of the first insulating layer, thus forming an N3 winding, completing the conductor foil winding on the first insulating layer; S7. First, place the first magnetic core in front of the frame and partially embed it in the frame. Then, place the second magnetic core opposite the first magnetic core, place the second magnetic core behind the frame and partially embed it in the frame, and let the winding surround the first magnetic core and the part of the second magnetic core embedded in the frame.

6. The method for manufacturing a horizontal transformer according to claim 5, characterized in that: In step S1, a circuit board is also prepared; It also includes the following steps: S8. Solder the first lead end, the second lead end, and the first and second soldering parts of both the first conductor foil and the second conductor foil to the circuit board, and all of them extend out of the same end face of the circuit board.

7. The method for manufacturing a horizontal transformer according to claim 6, characterized in that: In step S1, magnetic core wrapping tape is also prepared; It also includes the following steps: S9. Wrap the first and second magnetic cores with core-wrapping tape.

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