A split-type network transformer and its manufacturing method

Abstract

This invention provides a split-type network transformer and its manufacturing method. The network transformer is installed by fitting a base and a top cover shell. An isolation plate on the top cover shell forms an isolation and heat dissipation cavity, isolating the iron cores of the wound coils from each other. This prevents the instantaneous high voltage generated on the coil group from breaking through the insulation layer of the enameled wire and coupling to another coil group, thus damaging the network equipment. Simultaneously, multiple heat dissipation holes are provided on the isolation plate and the top cover shell to dissipate heat and prevent excessive internal temperature. A gap-cut cavity is formed between the support plate and the side of the base, ensuring stable signal transmission of the transformer while preventing internal risks.

Description

Technical Field

[0001] This invention relates to the field of network transformers; specifically, to a split-type network transformer and its manufacturing method. Background Technology

[0002] A network transformer is an electronic device used in network communication. Its purpose is to transfer telecommunication signals from one circuit to another, that is, from one electrical component to another, while changing the voltage and current of the signal. Network transformers are commonly used in computer networks, telephone networks, and broadcast television networks. Currently, network transformers are most commonly used in the communications field, typically to isolate different communication systems. Incompatibility issues may exist between the electrical signals of different communication systems; using a network transformer can isolate different communication systems, avoiding signal interference and loss. A network transformer generally consists of an input coil, an output coil, and an iron core. Patent CN101572177A discloses a network transformer, including an insulating shell, metal contacts, and multiple coil groups electrically connected to the metal contacts. It solves the problem that instantaneous high voltage generated on a coil group may break through the insulation layer of the enameled wire and couple to another coil group, thus damaging the network equipment. It uses insulating partitions to isolate adjacent coil groups, achieving mutual isolation between coil groups. The effect is good; however, this creates a problem: the inside of a coil group becomes a sealed space due to the presence of the insulating partition, making it difficult to dissipate heat and detect temperature, current, and voltage signals. Patent CN115863009A discloses a method for manufacturing a network transformer, the network transformer itself, and a circuit board. To improve heat dissipation inside the network transformer, multiple enameled wires of the transformer coil are inserted into multiple through-holes in the housing, with each enameled wire corresponding to a specific through-hole. Then, thermally conductive adhesive is applied to the coil and fills the cavity. Finally, the enameled wires in each through-hole are de-enameled and tinned to enable electrical connection, resulting in the finished transformer. This manufacturing method effectively integrates the coil with the cavity and housing holes, enhancing the stability and heat dissipation of the entire network transformer. However, it also presents a problem: the network transformer may be internally damaged when the input or output current or voltage is too high or the temperature is too high. If the coil and housing holes are integrated and wound around external pins, it is difficult to quickly disconnect the coil from the external connection in such situations. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a discrete network transformer and its manufacturing method.

[0004] A split-type network transformer and its manufacturing method include a base and an upper cover shell connected to the base. The base has an internal cavity, and N iron cores are installed inside the cavity. The N iron cores are arranged along the side of the base in the cavity. The base and the upper cover shell can be connected by fitting. After the base and the upper cover shell are connected, they can form an isolation heat dissipation cavity and a gap cutting cavity.

[0005] Furthermore, the base has multiple pins connected to the outside along the side of the base. The pins include a horizontal plate and a vertical plate. The horizontal plate is fixedly connected to the outside of the side of the base. One end of the vertical plate is connected to the horizontal plate, and the other end of the vertical plate is vertically downward connected to the outside.

[0006] Furthermore, a through hole is provided between adjacent pins on the outer side of the base. The through hole passes through the side of the base and faces the internal cavity of the base. There is a certain distance between the through hole and the pins on both sides.

[0007] Furthermore, multiple locking blocks are provided on the upper surface of both sides of the base along the side direction. N coils are wound around the N iron cores inside the base cavity. After the coils are wound around the iron cores n times, the free ends extend out of the outside of the base through the isolation heat dissipation cavity and the gap cutting cavity and are wound around the PIN pins on the outside of the base.

[0008] Furthermore, the base is equipped with a temperature detection device, an input current detection device, an input voltage detection device, an output current detection device, and an output voltage detection device.

[0009] Furthermore, the number of isolation and heat dissipation cavities is the same as the number of iron cores. Each iron core transmits independent current and voltage signals and dissipates heat within the isolation and heat dissipation cavity. The gap cutting cavity accommodates the free ends of the N coils extending from the N iron cores and dissipates heat again within the gap cutting cavity.

[0010] Furthermore, the upper cover shell includes a top cover, on which multiple ventilation and heat dissipation holes I are provided. Support plate I and support plate II are fixedly connected to the lower end of the top cover along its side. The width of the top cover is equal to the width of the base. Multiple slots are provided on both sides of the bottom end of the top cover, and these slots correspond one-to-one with multiple locking blocks on the upper surface of the two sides of the base. The distance between support plate I and one side of the top cover is L1, and the distance between support plate II and the other side of the top cover is L. 2， L1 = L2.

[0011] Furthermore, N+1 isolation plates are fixedly connected between support plate I and support plate II. One end of the isolation plate is fixedly connected to support plate I, and the other end of the isolation plate is fixedly connected to support plate II. N cavities are formed between the N+1 isolation plates.

[0012] Furthermore, the length of the isolation plate is the same as the depth of the cavity inside the base.

[0013] Furthermore, each isolation plate has a heat dissipation and ventilation strip running through it at the top, and multiple ventilation and heat dissipation holes II running through it at the bottom of each isolation plate.

[0014] Furthermore, when the top cover is attached to the base, N isolation heat dissipation cavities are formed between the N+1 isolation plates inside the cavity of the base.

[0015] Furthermore, on the support plate I and support plate II of the upper cover shell, there are N corresponding through-cut holes at the positions of the N isolation heat dissipation cavities.

[0016] Furthermore, the through-cutting hole is divided into an upper hole and a lower hole, which are separated by a partition plate. A notch is provided on the side of the through-partition hole, which penetrates into the interior of support plate I and support plate II. A cylinder is installed inside the notch of support plate I and support plate II. The cylinder is connected to the partition plate through a telescopic rod. The partition plate moves back and forth inside the notch and inside the through-partition hole, thereby closing or opening the through-cutting hole divided into an upper hole and a lower hole.

[0017] Furthermore, a coil cutting device is installed inside the lower hole.

[0018] Furthermore, the upper cover shell is also equipped with a control device for controlling the extension and retraction of the cylinder.

[0019] Furthermore, when the upper cover shell is fitted onto the base, a gap cutting cavity is formed between support plate I and support plate II and the two sides of the base.

[0020] Furthermore, both support plate I and support plate II are provided with multiple ventilation and heat dissipation holes III.

[0021] A method for manufacturing a split-type network transformer includes the following steps: Step 1: Initially, the base and the top cover shell are separated, and N iron cores are fixedly installed in the cavity of the base, and the distance between the N iron cores is set to be equal during installation.

[0022] Step 2: After installing N iron cores, wind the coil around the iron cores n times. After winding, pull out the free end of the coil.

[0023] Step 3: After winding the coil, put down the upper cover shell and fit it with the base. The support plate I and support plate II at the lower end of the upper cover shell enter the cavity. Before the slot of the upper cover shell and the block of the base are engaged, extend the free ends of the coils on the N iron cores out of the upper holes of the cutting holes, cut the cavity through the gap formed by the support plate and the side of the base, and then pass through the through holes on the side of the base to the outside of the base and wind them with the pins.

[0024] Step 4: After winding the coil around the pin, continue to lower the top cover shell so that the slot on the top cover shell and the block on the base cooperate. N isolation heat dissipation cavities are formed between the N+1 isolation plates inside the cavity of the base. The iron core of each wound coil is placed in the isolation heat dissipation cavity to transmit current and voltage signals and dissipate heat.

[0025] Step 5: After the top cover and base are properly installed, cover the coil inside the heat dissipation cavity with thermally conductive adhesive to ensure a firm connection between the coil, the iron core, and the heat dissipation cavity.

[0026] Step Six: Continue to use the normal winding connection method for the coils outside the gap cutting cavity and the base.

[0027] Step 7: During signal transmission, the internal temperature, input current and voltage, and output current and voltage of the transformer are detected. If the above values ​​are found to be greater than the standard values ​​and a risk is generated, the control device controls the partition plate to retract, so that the upper and lower holes open, the coil falls into the lower hole through the cutting hole and is cut off.

[0028] This invention uses a base and a top cover shell to install a network transformer. An isolation heat dissipation cavity formed by an isolation plate on the top cover shell isolates the iron cores of the wound coils from each other, preventing instantaneous high voltage generated on the coil group from breaking through the insulation layer of the enameled wire and coupling to another coil group, thus damaging the network equipment. Simultaneously, multiple heat dissipation holes are provided on the isolation plate and the top cover shell to dissipate heat and prevent excessive internal temperature. A gap cutting cavity is formed between the support plate and the side of the base. A through-hole cutting hole on the support plate and a through-hole on the base allow the coil to pass through both holes and extend outside the base simultaneously. Through the connection of a control device and a detection device, in the event of an internal transformer risk, the upper and lower holes of the through-hole cutting hole can be opened, allowing the coil to enter the lower hole and be cut off. The coil inside the isolation heat dissipation cavity is connected to the iron core and the cavity by thermally conductive adhesive, ensuring a stable connection. Furthermore, the coil inside the gap cutting cavity can be cut off according to the internal conditions of the transformer, ensuring stable signal transmission and preventing internal transformer risks. Attached Figure Description

[0029] Appendix Figure 1 This is a schematic diagram of the base.

[0030] Appendix Figure 2 This is a schematic diagram of the top cover.

[0031] Appendix Figure 3 This is a schematic diagram of a network transformer.

[0032] Appendix Figure 4 This is a schematic diagram of the cutting hole.

[0033] Appendix Figure 5 This is a schematic diagram of the gap cutting cavity.

[0034] Appendix Figure 6 This diagram illustrates the closed and open states of the cutting hole.

[0035] 1-Base, 2-Card block, 3-PIN pin, 4-Iron core, 5-Coil, 6-Through hole, 7-Upper cover shell, 8-Card slot, 9-Support plate I, 10-Support plate II, 11-Ventilation and heat dissipation hole III, 12-Through cutting hole, 13-Isolation plate, 14-Ventilation and heat dissipation hole II, 15-Isolation and heat dissipation cavity, 16-Divider plate, 17-Notch, 18-Gap cutting cavity. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] A split-type network transformer includes a base 1 and a top cover shell 7 connected to the base 1. The base 1 has an internal cavity, and N iron cores 4 are installed inside the cavity. The N iron cores 4 are arranged along the side of the base 1 within the cavity. The base 1 and the top cover shell 7 can be connected by a mating joint. After the base 1 and the top cover shell 7 are connected, they form an isolation and heat dissipation cavity 15 and a gap cutting cavity 18. The exterior of the base 1 has multiple pins 3 connected to the outside along the side of the base. The pins 3 include horizontal plates and vertical plates. The horizontal plate and the base are fixedly connected to the outside of the side. One end of the vertical plate is connected to the horizontal plate, and the other end of the vertical plate is vertically downward and connected to the outside. A through hole 6 is provided between adjacent pins 3 on the outer side of the base 1. The through hole 6 passes through the side of the base and faces the internal cavity of the base. There is a certain distance between the through hole 6 and the pins 3 on both sides. Multiple locking blocks 2 are provided on the upper surface of the two sides of the base 1 along the side direction. N coils 5 are wound around N iron cores 4 inside the base cavity. The coils 5 are wound around the iron cores n times. The free end extends out of the base through the isolation heat dissipation cavity and the gap cutting cavity and is wrapped around the PIN 3 on the outside of the base. The base 1 is equipped with a temperature detection device, an input current detection device, an input voltage detection device, an output current detection device, and an output voltage detection device. The number of isolation heat dissipation cavities 15 is the same as the number of iron cores. Each iron core 4 transmits independent current and voltage signals and dissipates heat in the isolation heat dissipation cavity. The gap cutting cavity accommodates the free ends of N coils 5 extending from N iron cores 4 and dissipates heat again in the gap cutting cavity. The upper cover shell 7 includes a top cover with multiple ventilation and heat dissipation holes I. The lower end of the top cover is fixedly connected to a support plate I 9 and a support plate II 10 along the side of the top cover. The width of the top cover is equal to the width of the base 1. Multiple slots 8 are provided on both sides of the bottom end of the top cover. The multiple slots 8 correspond one-to-one with the multiple blocks 2 on the upper surface of the two sides of the base. The distance from the support plate I 9 to one side of the top cover is L1, and the distance from the support plate II 10 to the other side of the top cover is L. 2，L1 = L2. N+1 isolation plates 13 are fixedly connected between support plate I9 and support plate II10. One end of isolation plate 13 is fixedly connected to support plate I9, and the other end of isolation plate 13 is fixedly connected to support plate II10. N+1 isolation plates form N cavities. The length of isolation plate 13 is the same as the depth of the cavity inside the base. Each isolation plate 13 has a heat dissipation and ventilation strip penetrating through it at its upper end. Multiple ventilation and heat dissipation holes II14 are provided through each isolation plate at the lower end of the heat dissipation and ventilation strip. When the upper cover shell is fitted onto the base, N isolation and heat dissipation cavities 15 are formed between the N+1 isolation plates inside the cavity of the base. N corresponding through-cut holes are provided on support plate I9 and support plate II10 of the upper cover shell at the positions corresponding to the N isolation and heat dissipation cavities 15. 12. The through-cutting hole 12 is divided into an upper hole and a lower hole, which are separated by a partition plate 16. A notch 17 is provided on the side of the through-partition hole. The notch 17 penetrates into the interior of support plate I and support plate II 10. A cylinder is provided inside support plate I and support plate II in the notch 17. The cylinder is connected to the partition plate through a telescopic rod. The partition plate moves back and forth inside the notch 17 and the through-partition hole, thereby closing or opening the through-cutting hole divided into an upper hole and a lower hole. A coil cutting device is provided in the lower hole. A control device for controlling the extension and retraction of the cylinder is also provided on the upper cover shell. When the upper cover shell is connected to the base, a gap cutting cavity 18 is formed between support plate I 9 and support plate II 10 and the two sides of the base. Multiple ventilation and heat dissipation holes Ⅲ 11 are provided on support plate I 9 and support plate II 10.

[0038] A method for manufacturing a split-type network transformer includes the following steps: Step 1: Initially, the base and the top cover shell are separated, and N iron cores are fixedly installed in the cavity of the base, and the distance between the N iron cores is set to be equal during installation.

[0039] Step 2: After installing N iron cores, wind the coil around the iron cores n times. After winding, pull out the free end of the coil.

[0040] Step 3: After winding the coil, put down the upper cover shell and fit it with the base. The support plate I and support plate II at the lower end of the upper cover shell enter the cavity. Before the slot of the upper cover shell and the block of the base are engaged, extend the free ends of the coils on the N iron cores out of the upper holes of the cutting holes, cut the cavity through the gap formed by the support plate and the side of the base, and then pass through the through holes on the side of the base to the outside of the base and wind them with the pins.

[0041] Step 4: After winding the coil around the pin, continue to lower the top cover shell so that the slot on the top cover shell and the block on the base cooperate. N isolation heat dissipation cavities are formed between the N+1 isolation plates inside the cavity of the base. The iron core of each wound coil is placed in the isolation heat dissipation cavity to transmit current and voltage signals and dissipate heat.

[0042] Step 5: After the top cover and base are properly installed, cover the coil inside the heat dissipation cavity with thermally conductive adhesive to ensure a firm connection between the coil, the iron core, and the heat dissipation cavity.

[0043] Step Six: Continue to use the normal winding connection method for the coils outside the gap cutting cavity and the base.

[0044] Step 7: During signal transmission, the internal temperature, input current and voltage, and output current and voltage of the transformer are detected. If the above values ​​are found to be greater than the standard values ​​and a risk is generated, the control device controls the partition plate to retract, so that the upper and lower holes open, the coil falls into the lower hole through the cutting hole and is cut off.

Claims

1. A split-type network transformer, comprising a base and a top cover shell connected to the base, wherein the base has an internal cavity and N iron cores are installed inside the cavity; the N iron cores are arranged along the side of the base within the cavity; the base and the top cover shell can be connected by a mating joint, forming an isolation and heat dissipation cavity and a gap-cutting cavity after connection; multiple pins for external connection are provided on the outside of the base along the side of the base, each pin including a horizontal plate and a vertical plate; the horizontal plate is fixedly connected to the outside of the side of the base; one end of the vertical plate is connected to the horizontal plate; the other end of the vertical plate is vertically downward connected to the outside; the outside of the base... A through-hole is provided between adjacent pins on the upper part of the base. The through-hole passes through the side of the base and faces the internal cavity of the base. There is a certain distance between the through-hole and the pins on both sides. The upper cover shell includes a top cover with multiple ventilation and heat dissipation holes I. Support plate I and support plate II are fixedly connected to the lower end of the top cover along the side of the top cover. The width of the top cover is equal to the width of the base. Multiple slots are provided on both sides of the bottom end of the top cover. The multiple slots correspond one-to-one with multiple locking blocks on the upper surface of the two sides of the base. The distance between support plate I and one side of the top cover is L1, and the distance between support plate II and the other side of the top cover is L. 2， L1=L2; N+1 isolation plates are fixedly connected between support plate I and support plate II. One end of each isolation plate is fixedly connected to support plate I, and the other end is fixedly connected to support plate II. N+1 isolation plates form N cavities. The length of each isolation plate is the same as the depth of the cavity inside the base. Each isolation plate has a heat dissipation and ventilation strip running through it at its upper end. Multiple ventilation holes II are provided through each isolation plate at the lower end of the ventilation strip. When the upper cover is fitted onto the base, N+1 isolation plates within the cavity inside the base form... N isolation and heat dissipation cavities are provided on the support plates I and II of the upper cover shell, corresponding to the positions of the N isolation and heat dissipation cavities, with N corresponding through-cut holes. The through-cut holes are divided into upper holes and lower holes, which are separated by a partition plate. The side of the through-partition hole is provided with a notch, which penetrates into the interior of support plates I and II. A cylinder is provided inside support plates I and II, and the cylinder is connected to the partition plate through a telescopic rod. The partition plate moves back and forth inside the notch and the through-partition hole, thereby closing or opening the through-cut holes, which are divided into upper holes and lower holes.

2. The split-type network transformer according to claim 1, characterized in that: Multiple locking blocks are set on the upper surface of both sides of the base along the side direction. N coils are wound on N iron cores inside the base cavity. After the coils are wound on the iron cores n times, the free ends extend out of the outside of the base through the isolation heat dissipation cavity and the gap cutting cavity and are wound on the pins on the outside of the base.

3. The split-type network transformer according to claim 2, characterized in that: The base is equipped with a temperature detection device, an input current detection device, an input voltage detection device, an output current detection device, and an output voltage detection device.

4. The split-type network transformer according to claim 3, characterized in that: The number of isolation and heat dissipation cavities is the same as the number of iron cores. Each iron core transmits independent current and voltage signals and dissipates heat within the isolation and heat dissipation cavity. The gap cutting cavity accommodates the free ends of the N coils extending from the N iron cores and dissipates heat again within the gap cutting cavity.

5. The split-type network transformer according to claim 4, characterized in that: A coil cutting device is installed in the lower hole, and a control device for controlling the extension and retraction of the cylinder is also installed on the upper cover shell. When the upper cover shell is connected to the base, a gap cutting cavity is formed between the support plate I and the support plate II and the two sides of the base. Multiple ventilation and heat dissipation holes III are provided on both the support plate I and the support plate II.

6. A method for manufacturing the split-type network transformer according to any one of claims 1-5, comprising the following steps: Step 1: Initially, separate the base and the top cover shell, fix N iron cores in the cavity of the base, and set the distance between the N iron cores to be equal during installation; Step 2: After installing N iron cores, wind the coil around the iron cores n times, and then pull out the free end of the coil. Step 3: After winding the coil, put down the upper cover shell and fit it with the base. The support plate I and support plate II at the lower end of the upper cover shell enter the cavity. Before the slot of the upper cover shell and the block of the base are engaged, extend the free ends of the coils on the N iron cores out of the upper holes of the cutting holes, cut the cavity through the gap formed by the support plate and the side of the base, and then pass through the through holes on the side of the base to the outside of the base and wind them with the pins.

7. The manufacturing method according to claim 6, characterized in that: Step 4: After winding the coil around the pin, continue to lower the top cover shell so that the slot on the top cover shell and the block on the base cooperate. N isolation heat dissipation cavities are formed between N+1 isolation plates in the cavity inside the base. The iron core of each wound coil is placed in the isolation heat dissipation cavity to transmit current and voltage signals and dissipate heat. Step 5: After the top cover and base are properly installed, cover the coil inside the heat dissipation cavity with thermally conductive adhesive to ensure a firm connection between the coil and the iron core and the heat dissipation cavity. Step Six: Continue to use the normal winding connection method for the coils outside the gap cutting cavity and the base; Step 7: During signal transmission, the internal temperature, input current and voltage, and output current and voltage of the transformer are detected. If the internal temperature, input current and voltage, and output current and voltage values ​​are found to be greater than the standard values ​​and pose a risk, the control device controls the partition plate to retract, causing the upper and lower holes to open, and the coil falls into the lower hole through the cutting hole and is cut off.

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