Magnetic core preparation method and magnetic core assembly for transformer

Abstract

The present application provides a method for preparing a magnetic core for a transformer and a magnetic core assembly, which is used to prepare a magnetic core assembly for a transformer, wherein the assembly includes a first magnetic core, a second magnetic core and a winding module, wherein the first magnetic core and the second magnetic core are both formed with a first side column, a second side column and at least one middle column, wherein a first accommodating cavity is formed in the winding module, wherein the winding module is arranged on the first magnetic core, each middle column is arranged in the first accommodating cavity, and the second magnetic core is bonded to the first magnetic core toward the winding module; the method includes: cleaning the first magnetic core and the second magnetic core respectively to remove impurities and oxide layers of the first magnetic core and the second magnetic core; placing the winding module on the first magnetic core or the second magnetic core after cleaning; determining the first side column, the second side column and the middle column of the first magnetic core and the second magnetic core as bonding areas, and using a preset adhesive to bond the first magnetic core and the second magnetic core through the bonding areas; and the adhesive is made of resin material. The assembly error of the transformer during the assembly process is reduced to within ±%1.

Description

Technical Field

[0001] The present application relates to the technical field of transformers, and in particular to a method for preparing a magnetic core and a magnetic core assembly for a transformer. Background Art

[0002] Transformers are indispensable equipment in power systems, used to convert alternating current of one voltage level into alternating current of another voltage level. In the design and manufacture of transformers, the bonding between the core and the winding module is a crucial step, which not only ensures the structural stability between the two components, but also improves the electrical performance and thermal stability.

[0003] The traditional bonding between the magnetic core and the winding module uses solder, insulating glue and non-conductive adhesive as bonding materials, which has problems such as generating a lot of heat, long curing time and insufficient insulation performance.

[0004] Therefore, there is an urgent need for a method for preparing a magnetic core for a transformer to solve at least one of the above problems. Summary of the invention

[0005] The present application provides a method for preparing a magnetic core for a transformer and a magnetic core assembly, which aims to solve the problems that the bonding between the traditional magnetic core and the winding module is performed by using solder, insulating glue and non-conductive adhesive as bonding materials, and there are problems such as generating a lot of heat, a long curing time, and the insulation performance may not be good enough. The method provided can greatly reduce the assembly error of the transformer during the assembly process. The assembly error will affect the inductance and leakage inductance of the transformer. The traditional process error is generally ±%7 to %10. The method provided can control the assembly error within ±%1 after testing.

[0006] In a first aspect, the present application provides a method for preparing a magnetic core assembly for a transformer, which is used to prepare a magnetic core assembly for a transformer, wherein the magnetic core assembly includes a first magnetic core, a second magnetic core and a winding module, wherein the first magnetic core and the second magnetic core are both formed with a first side column, a second side column and at least one middle column, and at least one first accommodating cavity is formed in the winding module, the winding module is arranged on the first magnetic core, each middle column is arranged in the first accommodating cavity, and the second magnetic core is bonded to the first magnetic core toward the winding module; the method includes:

[0007] Cleaning the first magnetic core and the second magnetic core respectively to remove impurities and oxide layers of the first magnetic core and the second magnetic core;

[0008] placing the winding module on the cleaned first magnetic core or the second magnetic core;

[0009] The first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are determined as bonding areas, and a preset adhesive is used to bond the first magnetic core and the second magnetic core through the bonding area; wherein the adhesive is made of resin material.

[0010] In some embodiments, the first magnetic core and the second magnetic core are cleaned separately, including: using a copper brush to clean the first magnetic core and the second magnetic core separately to roughen the surface of the first magnetic core and the second magnetic core to increase the contact area between the adhesive and the first magnetic core and the second magnetic core.

[0011] In some embodiments, the first magnetic core and the second magnetic core are bonded via a bonding area using a preset adhesive, including: using a solder resist composed of epoxy resin and a curing agent to bond the first magnetic core and the second magnetic core via the bonding area; and / or the solder resist is green glue.

[0012] In some embodiments, if there are multiple middle columns, the bodies of the first magnetic core and the second magnetic core also include at least one third side column, and each third side column is arranged between two adjacent middle columns; the first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are determined as bonding areas, including: respectively determining the first side column, the second side column, the third side column and the middle column of the first magnetic core and the second magnetic core as bonding areas, so as to use a preset adhesive to bond the first magnetic core and the second magnetic core through the bonding area.

[0013] In some embodiments, the magnetic core assembly also includes a mounting piece, and the mounting piece and the winding module both include multiple mounting holes; after the first magnetic core and the second magnetic core are bonded using a preset adhesive, it also includes: a fixed connection between the mounting piece, the first magnetic core, the second magnetic core and the winding module is achieved through the mounting holes connected to the winding module.

[0014] In a second aspect, the present application provides a magnetic core assembly for a transformer, characterized in that the magnetic core assembly comprises:

[0015] A first magnetic core and a second magnetic core, wherein the first magnetic core and the second magnetic core are both provided with a first side column, a second side column and at least one middle column;

[0016] A winding module, wherein at least one first accommodating cavity is formed in the winding module, the winding module is arranged on the first magnetic core or the second magnetic core, and each middle column is arranged in the first accommodating cavity;

[0017] The first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are bonding areas, and a preset adhesive is used to bond the first magnetic core and the second magnetic core through the bonding area; wherein the adhesive is made of resin material.

[0018] In some embodiments, the shape of the first accommodating cavity is compatible with the shape of the middle column; and / or the shape of the middle column is any one of circular, rectangular, elliptical, and diamond.

[0019] In some embodiments, if there are multiple middle columns and the length of each middle column along a preset direction is greater than a preset length, a third side column is also formed on the body of the first magnetic core; wherein the preset direction is the direction along the first side column pointing to the second side column.

[0020] Exemplarily, the winding module further includes: at least one second accommodating area, the shape of the second accommodating area is adapted to the shape of the third side column, and each third side column is arranged in the second accommodating area.

[0021] Exemplarily, each third side column forms a bonding area with the middle column, the first side column and the second side column.

[0022] The present application discloses a method for preparing a magnetic core for a transformer and a magnetic core assembly. The method first cleans the first magnetic core and the second magnetic core to remove impurities and oxide layers on their surfaces. This step is to ensure that the bonding surface is clean and flat, thereby improving the reliability and stability of bonding. After cleaning, the winding module is placed on the first magnetic core / the second magnetic core, ensuring that the first accommodating cavity in the winding module is aligned with the middle column of the first magnetic core. The winding module is usually composed of multiple layers of insulating materials and wire windings, and its structure and position design can effectively reduce electromagnetic interference. The first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are determined as bonding areas. This is to ensure the bonding strength of the magnetic core at key positions, thereby improving the mechanical stability and electrical performance of the entire magnetic core assembly. At the same time, a preset resin material is used as an adhesive to bond the first magnetic core and the second magnetic core in the bonding area. The resin has good mechanical strength, high temperature resistance and insulation properties, and can effectively solve the problems existing in traditional bonding materials. At the same time, the provided method can significantly reduce the assembly error of the transformer during the assembly process. The assembly error will affect the inductance and leakage inductance of the transformer. The traditional process error is generally ±%7 to 10%. The provided method can control the assembly error within ±%1 after testing.

[0023] The method provided has at least the following beneficial effects

[0024] 1. Reduce heat generation: Compared with traditional solder and insulating glue, the curing process of resin generates less heat. This can effectively reduce the temperature rise caused by the thermal effect of the bonding material during the use of the transformer, thereby improving the thermal stability of the transformer.

[0025] 2. Shorten the curing time: The curing time of the resin is relatively short, and the bonding process can be completed in a shorter time. This is of great significance for improving production efficiency and reducing costs.

[0026] 3. Improve insulation performance: Resin has excellent insulation performance and can effectively prevent current leakage and short circuit. This not only improves the safety of the transformer, but also extends its service life.

[0027] 4. Enhanced mechanical strength: The high mechanical strength of the resin can provide good support and fixation in the bonding area, thereby improving the overall mechanical stability of the core assembly. This is especially important for the performance of the transformer in high vibration and shock environments.

[0028] 5. Improve the production process: This method improves the quality and reliability of bonding by cleaning the core surface in advance to ensure that the bonding area is clean and free of impurities. In addition, the placement and alignment process of the winding module is also more precise, which helps to reduce errors and defective product rates in production.

[0029] In summary, the method provided solves some key problems in the preparation of traditional transformer core components by improving the preparation process of the core and using high-performance resin adhesives. Specifically, it reduces heat generation, shortens curing time, improves insulation performance and mechanical strength, and thus improves the overall performance and reliability of the transformer. This has important practical significance for the application of high-performance and high-stability transformers.

[0030] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0032] Figure 1 It is a structural schematic diagram of the first magnetic core assembly provided in one embodiment of the present application;

[0033] Figure 2 is a schematic structural diagram of a first magnetic core or a second magnetic core provided in an embodiment of the present application;

[0034] Figure 3 is a structural schematic diagram of a winding module provided in an embodiment of the present application;

[0035] Figure 4 It is a schematic diagram of the placement of the magnetic core and windings provided in one embodiment of the present application;

[0036] Figure 5 is a structural schematic diagram of a second magnetic core assembly provided in an embodiment of the present application;

[0037] Figure 6 It is a structural schematic diagram of the third type of magnetic core assembly provided in one embodiment of the present application.

[0038] Figure 7 is a schematic flow chart of the steps of a method for preparing a magnetic core for a transformer provided in one embodiment of the present application;

[0039] Figure 8 It is a schematic block diagram of the structure of a transformer provided in one embodiment of the present application.

[0040] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. DETAILED DESCRIPTION

[0041] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0042] The flowcharts shown in the accompanying drawings are only examples and do not necessarily include all the contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps may also be decomposed, combined or partially merged, so the actual execution order may change according to actual conditions.

[0043] It should be understood that, in order to facilitate the clear description of the technical solutions of the embodiments of the present invention, in the embodiments of the present invention, the words "first", "second", etc. are used to distinguish the same items or similar items with substantially the same functions and effects. Those skilled in the art can understand that the words "first", "second", etc. do not limit the quantity and execution order, and the words "first", "second", etc. do not necessarily limit the difference.

[0044] It should be understood that the terms used in this application specification are only for the purpose of describing specific embodiments and are not intended to limit the application. As used in this application specification and the appended claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to include plural forms.

[0045] It should also be understood that the term “and / or” used in the specification and appended claims refers to any and all possible combinations of one or more of the associated listed items, and includes these combinations.

[0046] In conjunction with the accompanying drawings, some embodiments of the present application are described in detail below. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0047] Transformers are indispensable equipment in power systems, used to convert alternating current of one voltage level into alternating current of another voltage level. In the design and manufacture of transformers, the bonding between the core and the winding module is a crucial step, which not only ensures the structural stability between the two components, but also improves the electrical performance and thermal stability.

[0048] The traditional bonding between the magnetic core and the winding module uses solder, insulating glue and non-conductive adhesive as bonding materials, which has problems such as generating a lot of heat, long curing time and insufficient insulation performance.

[0049] Therefore, there is an urgent need for a method for preparing a magnetic core for a transformer to solve at least one of the above problems.

[0050] To solve the above problems, please refer to Figures 1 to 6 , Figure 1 Schematic diagram of the structure of a magnetic core assembly provided by an embodiment of the present application. Figure 1 As shown, the magnetic core assembly 10 includes a first magnetic core 11, a second magnetic core 12 and a winding module 13, and the first magnetic core 11 and the second magnetic core 12 are both formed with a first side column 111 / 121, a second side column 112 / 122 and at least one middle column 113 / 123 on their bodies; at least one first accommodating cavity is formed in the winding module 13, the winding module 13 is arranged on the first magnetic core 11 or the second magnetic core 12, and each middle column 113 / 123 is arranged in the first accommodating cavity; wherein, the first side column 111 / 121, the second side column 112 / 122 and the middle column 113 / 123 of the first magnetic core 11 and the second magnetic core 12 are bonding areas, and the first magnetic core 11 and the second magnetic core 12 are bonded via the bonding areas using a preset adhesive; wherein, the adhesive is made of resin material.

[0051] Specifically, the provided magnetic core assembly 10 is mainly composed of three parts: a first magnetic core 11, a second magnetic core 12 and a winding module 13. The first magnetic core 11 and the second magnetic core 12 both have a first side column 111 / 121, a second side column 112 / 122 and at least one middle column 113 / 123. The winding module 13 is internally designed with a first accommodating cavity matching the middle column 113 / 123, which is used to accommodate the middle column 113 / 123 and enhance the assembly stability between the magnetic core and the winding module 13. The bonding between the first magnetic core 11 and the second magnetic core 12 is carried out in the bonding area formed by their first side column 111 / 121, the second side column 112 / 122 and the middle column 113 / 123. A resin material is used as an adhesive to firmly bond the first magnetic core 11 and the second magnetic core 12 together through the bonding area.

[0052] Furthermore, compared with the traditional method of bonding using solder, the resin material does not generate a large amount of heat during the curing process, which is conducive to maintaining the temperature stability of the component and avoiding the influence of high temperature on the winding and other sensitive components. The resin material can be cured quickly under appropriate conditions, which greatly shortens the curing time and improves production efficiency compared with insulating glue or some non-conductive adhesives. At the same time, the resin has excellent insulation properties, which can effectively avoid the problem of electrical performance degradation caused by insufficient insulation glue performance, and ensure the safety and reliability of the transformer under high voltage conditions. The corresponding resin material not only has good insulation performance, but also has high mechanical strength, which can enhance the connection strength between the first magnetic core 11 and the second magnetic core 12, improve the overall mechanical stability of the component, and prevent loosening or falling off during use. And by using resin materials for bonding in a specific bonding area, the assembly process between the winding module 13 and the magnetic core is simplified, and the production cost is reduced. The design of the first accommodating cavity makes the contact between the middle column 113 / 123 and the winding module 13 closer, which helps to improve the electromagnetic performance of the transformer, reduce magnetic field leakage, and improve efficiency.

[0053] In summary, the magnetic core assembly 10 effectively solves the problems existing in the traditional bonding method by using resin as the bonding material, combining the specific bonding area design and the structural optimization of the winding module 13, and significantly improves the performance, safety and production efficiency of the transformer. This innovative design provides a new and better solution for the transformer manufacturing field.

[0054] In some embodiments, when the magnetic core assembly 10 is applied to a high-frequency transformer, the number of the columns 113 / 123 can be multiple columns 113 / 123 (e.g., 3 or 5) to improve the uniformity of the distribution of the magnetic flux. The adhesive is selected as a fast-curing, high-temperature resistant resin material. The winding module 13 is a multi-layer winding to meet the needs of high-frequency applications.

[0055] In some embodiments, when the magnetic core assembly 10 is applied to a conventional transformer, the number of middle columns 113 / 123 can be a single middle column 113 / 123, which is suitable for lower frequency applications. The adhesive is selected as a resin material with a standard curing time. The winding module 13 is a single-layer or double-layer winding, which meets basic transformer requirements.

[0056] In some embodiments, Figure 3 As shown, the winding module 13 is a component containing the transformer winding, which is usually composed of a frame and a winding (coil) (not shown). The winding module 13 is formed with a first accommodating cavity (refer to Figure 3 and Figure 4 , an area for placing the middle column 113 / 123), used to accommodate the middle column 113 / 123 of the magnetic core.

[0057] In some embodiments, the shape of the first accommodating cavity is compatible with the shape of the middle column 113 / 123; and / or, the shape of the middle column 113 / 123 is any one of circular, rectangular, elliptical, and diamond.

[0058] The shape of the first accommodating cavity is designed to match the shape of the middle column 113 / 123. The shape of the middle column 113 / 123 can be any one of a circle, a rectangle, an ellipse or a diamond. Furthermore, the matching of the shape of the first accommodating cavity and the middle column 113 / 123 can ensure that the middle column 113 / 123 can be accurately embedded in the winding module 13, avoiding positional displacement during the assembly process and improving assembly accuracy. The adaptive shape design can increase the contact area between the middle column 113 / 123 and the winding module 13, thereby improving mechanical stability and reducing vibration and looseness. At the same time, shape adaptation can reduce the air gap between the middle column 113 / 123 and the winding module 13, optimize the magnetic field path, improve electromagnetic performance, and reduce magnetic leakage and energy loss. Finally, through the adaptive shape design, the skeleton design of the winding module 13 can be simplified, unnecessary complexity can be reduced, and production efficiency can be improved.

[0059] In some embodiments, if there are multiple middle columns 113 / 123 and the length of each middle column 113 / 123 along a preset direction is greater than a preset length, a third side column 114 / 124 is also formed on the body of the first magnetic core 11; wherein the preset direction is the direction along the first side column 111 / 121 pointing to the second side column 112 / 122.

[0060] If there are multiple middle pillars 113 / 123, the length of each middle pillar 113 / 123 along the direction from the first side pillar 111 / 121 to the second side pillar 112 / 122 (ie, the preset direction) is greater than the preset length. One or more third side pillars 114 / 124 are formed on the body of the first magnetic core 11.

[0061] The addition of the third side column 114 / 124 can provide additional support and enhance the mechanical strength of the first magnetic core 11, especially when the number of middle columns 113 / 123 is large and the length is long, which can prevent the magnetic core from being deformed or damaged. At the same time, the third side column 114 / 124 can serve as part of the heat conduction path to help disperse heat and improve overall thermal stability. The design of multiple middle columns 113 / 123 can optimize the distribution of the magnetic circuit, especially in high-frequency transformers, which helps to reduce magnetic losses and improve efficiency. The addition of the third side column 114 / 124 can increase the contact points between the magnetic core and the winding module 13, improve overall reliability, and reduce failures due to mechanical or electrical reasons.

[0062] For example, Figure 2As shown, the winding module 13 further includes: at least one second accommodating area, the shape of the second accommodating area is adapted to the shape of the third side column 114 / 124, and each third side column 114 / 124 is arranged in the second accommodating area.

[0063] The adaptive design of the second accommodation area and the third side column 114 / 124 can ensure that the third side column 114 / 124 can be accurately embedded in the winding module 13 to avoid assembly errors. The adaptive second accommodation area can provide additional mechanical support, enhance the connection strength between the winding module 13 and the first magnetic core 11, and reduce vibration and looseness. The design of the second accommodation area can promote uniform heat conduction, prevent local overheating, and improve thermal stability. The adaptive design of the second accommodation area can simplify the skeleton structure of the winding module 13, reduce unnecessary complexity, and improve production efficiency.

[0064] Exemplarily, each third side column 114 / 124 forms a bonding area with the middle column 113 / 123 , the first side column 111 / 121 , and the second side column 112 / 122 .

[0065] By extending the bonding area to the third side column 114 / 124, more bonding points can be provided, the connection strength between the first magnetic core 11 and the second magnetic core 12 can be enhanced, and the overall mechanical stability can be improved. Multiple bonding points can disperse stress, reduce mechanical or electrical failures caused by local stress concentration, and improve the reliability of the transformer. Resin materials have excellent insulation properties, and extending the bonding area can further improve the overall insulation properties and ensure the safe operation of the transformer under high voltage conditions. The resin has low heat during the curing process, and extending the bonding area can reduce the accumulation of heat in individual areas and improve the overall thermal stability.

[0066] In some embodiments, Figure 5 and Figure 6 As shown, the magnetic core assembly 10 further includes a mounting member 14, and the mounting member 14 and the winding module 13 both include a plurality of mounting holes (eg Figure 5 and Figure 6 The mounting member 14 is provided with a plurality of circular holes between the mounting member 14 and the winding module 13, so as to realize the fixed connection between the mounting member 14, the first magnetic core 11, the second magnetic core 12 and the winding module 13 through the mounting holes communicating with the winding module 13. The specific design can be based on actual needs, and the embodiment of the present application is not limited to this.

[0067] Please refer to Figure 7 , Figure 7 1 is a schematic flow chart of the steps of a method for preparing a magnetic core for a transformer provided in one embodiment of the present application. The provided method is used to prepare a magnetic core assembly provided in any embodiment of the present application. Figure 7 As shown, the provided method includes steps S101 to S103.

[0068] Step S101 . Clean the first magnetic core and the second magnetic core respectively to remove impurities and oxide layers of the first magnetic core and the second magnetic core.

[0069] Specifically, impurities and oxide layers on the surfaces of the first magnetic core and the second magnetic core are removed to ensure that the bonding surface is clean and flat. Physical cleaning (such as ultrasonic cleaning, sandblasting) or chemical cleaning (such as acid cleaning, solvent cleaning) can be used.

[0070] For example, by placing the magnetic core in an ultrasonic cleaning machine filled with cleaning fluid, the cavitation effect of ultrasound can be used to remove surface dirt and oxide layers. You can also use organic solvents such as ethanol and acetone to wipe the surface of the magnetic core to remove grease and other organic impurities.

[0071] The cleaned surface is free of impurities and oxide layers, allowing the adhesive to better contact the core surface, thereby improving the reliability and strength of the bond. After removing impurities and oxide layers, the insulation performance of the bonding surface is better, reducing potential conductive paths and improving the safety of the transformer. The corresponding clean surface reduces corrosion and aging, extending the service life of the core assembly.

[0072] In some embodiments, the first magnetic core and the second magnetic core are cleaned separately, including: using a copper brush to clean the first magnetic core and the second magnetic core separately to roughen the surface of the first magnetic core and the second magnetic core to increase the contact area between the adhesive and the first magnetic core and the second magnetic core.

[0073] By selecting the appropriate copper brush, ensure that the hardness and size of the brush are suitable for the surface treatment of the magnetic core. Copper brushes are usually made of soft and conductive copper wire, which can effectively remove surface impurities and roughen the surface. Check the surface of the first and second magnetic cores before cleaning to determine whether there are obvious impurities, oxide layers or other contaminants. If so, you can use a soft cloth or solvent for preliminary cleaning. Use a copper brush to brush the surface of the first and second magnetic cores. The specific operation is as follows: manually hold the copper brush and brush the surface of the magnetic core with appropriate force and angle to ensure uniform surface roughening, or use a mechanical device (such as an electric brush) to roughen the surface to ensure more uniform and efficient operation.

[0074] During the brushing process, control the force and angle of the copper brush to avoid excessive damage to the core surface. The appropriate force and angle can ensure a slight roughness on the surface without forming large scratches or damage. After the surface roughening is completed, check the roughness of the core surface to ensure that it has achieved the desired roughening effect. The surface should show uniform slight bumps and no obvious scratches or damage. Finally, use a detergent (such as alcohol) to clean the roughened surface to remove debris and residues generated during the brushing process. Dry the core surface thoroughly with dry compressed air or an oven to ensure that no moisture remains.

[0075] The brushing process with a copper brush can effectively roughen the surface of the magnetic core to form tiny concave and convex structures. These tiny structures increase the roughness of the surface, thereby increasing the contact area between the adhesive and the surface of the magnetic core. At the same time, increasing the contact area helps to improve the adhesion of the adhesive, thereby enhancing the bonding strength and reliability. For example, the roughened surface can form more "anchor points" at the microscopic level, allowing the adhesive to adhere more firmly to the surface of the magnetic core, reducing the risk of the adhesive separating from the surface.

[0076] At the same time, after the surface is roughened, the contact between the adhesive and the core surface is closer and more uniform, reducing the formation of bubbles and voids. The closer contact and uniform distribution enable the adhesive to better fill the tiny bumps on the surface, enhance the mechanical bonding force, and improve the bonding strength. For example, in the resin bonding process, the roughened surface can significantly reduce the bubbles in the bonding layer, thereby improving the density and strength of the bonding layer.

[0077] Accordingly, surface roughening can remove impurities and oxide layers on the surface, which may cause the insulation performance to deteriorate. After removing these impurities, the insulation performance of the surface will be improved, reducing the risk of current leakage and short circuit. For example, in high-frequency transformers, impurities and oxide layers may cause partial discharge. After surface roughening, these risks are significantly reduced, improving the insulation performance of the transformer.

[0078] Finally, by roughening the surface, we ensure that the adhesive has stronger adhesion to the core surface, reducing loosening and separation caused by poor bonding. The enhanced bonding quality improves the overall reliability of the core assembly and extends its service life. For example, in high vibration and impact environments, the roughened surface can provide higher mechanical stability, reduce loosening and separation of the core assembly, and ensure the long-term stable operation of the transformer. And the copper brush cleaning method is relatively simple and does not require complex equipment and technology. It is easy to operate, low cost, and easy to implement on the production line, which improves the operability and economy of the process. For example, in the production of small transformers, the use of copper brushes for surface roughening can significantly simplify the process flow and reduce equipment investment costs.

[0079] The above embodiment uses a copper brush to roughen the surface of the first magnetic core and the second magnetic core, thereby effectively increasing the contact area between the adhesive and the surface of the magnetic core, and improving the bonding quality and reliability. At the same time, surface roughening also improves insulation performance and reduces potential electrical failures. This method is simple to operate, low-cost, and suitable for production environments of all sizes. It is an effective means to improve the performance of transformer core components.

[0080] Step S102: placing the winding module on the cleaned first magnetic core or the second magnetic core.

[0081] Specifically, the winding module is precisely placed on the first magnetic core to ensure that each center column can be accurately aligned with the first accommodating cavity. Mechanical alignment tools (such as positioning pins, molds) or visual alignment systems (such as cameras, laser positioning) can be used. The precise alignment of the winding module and the magnetic core reduces errors in production, reduces the defective rate caused by poor alignment, and improves the yield rate.

[0082] In some embodiments, by designing positioning pins and positioning holes on the first magnetic core and the winding module, the positioning pins are inserted to ensure the precise alignment of the winding module. Or a high-precision camera and image processing software are used to automatically detect and adjust the position of the winding module to ensure that each center column is precisely aligned with the first accommodating cavity. Precisely aligned winding modules and magnetic cores can reduce electromagnetic interference and improve the electrical performance of the transformer. If a mechanical alignment tool or a visual alignment system is used, alignment can be completed quickly and accurately, improving production efficiency. At the same time, precise alignment reduces errors in production, reduces the defective rate caused by poor alignment, and improves the yield rate.

[0083] Step S103. Determine the first side column, the second side column and the middle column of the first magnetic core and the second magnetic core as the bonding area, and use a preset adhesive to bond the first magnetic core and the second magnetic core through the bonding area; wherein the adhesive is made of resin material.

[0084] By using a resin material as an adhesive, the resin can be an epoxy resin, a polyimide resin or other types of thermosetting resins. It has good mechanical strength, high temperature resistance and insulation properties. The first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are bonding areas, and these areas are the parts of the magnetic core assembly that need to be bonded. A dispensing machine or a manual glue application tool can be used to evenly apply the resin to the bonding area, and then the first magnetic core and the second magnetic core are bonded together.

[0085] In some embodiments, by using an automatic glue dispenser, the resin is evenly applied to the bonding area of ​​the first magnetic core (it can also be applied to the second magnetic core or both), and then the second magnetic core is aligned and bonded to the first magnetic core. Using a brush or a syringe, the resin is evenly applied to the bonding area, and then the second magnetic core is aligned and bonded to the first magnetic core.

[0086] Since the resin generates less heat during the curing process, the temperature rise caused by the thermal effect of the bonding material during the use of the transformer is reduced, and the thermal stability is improved. The curing time of the resin is relatively short, which can greatly improve production efficiency, reduce process time, and reduce production costs. In addition, the resin has excellent insulation properties, which can effectively prevent current leakage and short circuit phenomena, and improve the safety and service life of the transformer. At the same time, the resin has high mechanical strength and can provide good support and fixing in the bonding area, enhancing the overall mechanical stability of the core assembly, especially in high vibration and impact environments. Finally, the uniform application and rapid curing of the resin in the bonding area ensure the bonding strength and reliability between the cores, and reduce performance problems caused by poor bonding.

[0087] In summary, through the detailed description of the above steps S101 to S103, it can be seen that the method not only uses advanced technology and tools in the cleaning, alignment and bonding processes, but also uses resin in the selection of bonding materials. These improvements effectively solve the problems existing in the bonding of traditional magnetic cores and winding units, such as high heat generation, long curing time and poor insulation performance. Specifically, the bonding quality is improved by cleaning the surface to remove impurities and oxide layers; electromagnetic interference is reduced by accurately aligning the winding modules; and by using resin as an adhesive, the curing time is shortened and the insulation performance and mechanical strength are improved. These measures together improve the performance and reliability of the transformer core assembly and achieve efficient magnetic integration.

[0088] In some embodiments, a preset adhesive is used to bond the first magnetic core and the second magnetic core through a bonding area, including: using a solder mask composed of epoxy resin and a curing agent to bond the first magnetic core and the second magnetic core through the bonding area; and / or the solder mask is green glue or.

[0089] Solder resist (also called solder resist material or solder resist ink) is a resin material with good insulating properties and mechanical strength. It is commonly used in the manufacture of electronic circuit boards to cover pads and lines to prevent bridging and short circuits during soldering. By selecting a solder resist suitable for core bonding, ensure that it has good fluidity and curing properties to facilitate uniform application and rapid curing during the bonding process. Green glue generally refers to a special surface treatment material for printed circuit boards (PCBs). In the electronics manufacturing industry, green glue generally refers to the solder resist used on PCBs, which has a green appearance, hence the name. Resin is the main component of green glue, which provides the basis for curing. This application can use either LV151 green glue or EP3189 green glue. Among them, EP3189 green glue is a preferred embodiment of this application.

[0090] According to the design of the first magnetic core and the second magnetic core, determine the areas that need to be bonded, usually including the first side column, the second side column and the middle column. These areas are the parts of the magnetic core assembly that need to be bonded. Use a marking tool (such as a pencil or a marker) to mark the bonding area on the surface of the magnetic core for easy subsequent operations. Use a dispensing machine or a manual glue coating tool to evenly apply the solder mask to the bonding area. You can use spot coating, line coating or surface coating to ensure that the adhesive covers the entire bonding area. Control the thickness of the glue coating to ensure that the adhesive forms a uniform thin layer in the bonding area without accumulation or leakage. Usually the thickness is controlled between 0.1-0.3 mm.

[0091] Align the second core with the first core, ensuring that the bonding area is accurately aligned without deviation. Use a clamp or press to apply appropriate pressure to the bonding area to help the adhesive spread evenly and remove air bubbles. Use a fixing fixture or auxiliary tool to fix the position of the core during the bonding process to ensure alignment and stability.

[0092] According to the curing requirements of the solder resist adhesive, set appropriate curing conditions. Usually, heating curing is adopted, and the temperature and time are determined according to the curing curve of the adhesive. The common curing temperature is 80-120℃ and the time is 1-2 hours. Place the bonded core assembly in an oven or curing furnace and cure it according to the set temperature and time. During the curing process, keep the environment clean and avoid dust and impurities.

[0093] After curing is completed, check the appearance of the bonding area to ensure that there are no bubbles, cracks, and obvious adhesive overflow. At the same time, perform mechanical strength tests, insulation performance tests, and electrical performance tests to ensure that the bonding quality and performance of the core assembly meet the requirements.

[0094] Since solder resist adhesive has good insulation properties, it can effectively prevent current leakage and short circuit. It improves the insulation performance of the core component and enhances the safety and reliability of the transformer. For example, in high-frequency transformers, the insulation performance of the bonding area is crucial. Solder resist adhesive can effectively prevent partial discharge and improve the electrical safety of the transformer.

[0095] At the same time, solder resist adhesive has high mechanical strength and can provide good mechanical support and fixation in the bonding area. It can enhance the overall mechanical stability of the core assembly, especially in high vibration and impact environments. For example, in a high vibration environment, solder resist adhesive can provide higher bonding strength, reduce the loosening and separation of the core assembly, and ensure the long-term stable operation of the transformer.

[0096] Correspondingly, the curing time of solder resist adhesive is relatively short, and it can usually be cured within 1-2 hours. This shortens the process time, improves production efficiency, and reduces production costs. For example, in mass production, fast-curing solder resist adhesive can significantly reduce the curing waiting time, speed up production cycle, and increase production capacity.

[0097] Furthermore, the curing process of the solder resist adhesive generates less heat, which reduces the temperature rise caused by the thermal effect of the adhesive material during the use of the transformer. The thermal stability is improved, and the performance degradation and shortened life caused by the temperature rise are reduced. For example, in a high temperature environment, the low thermal effect of the solder resist adhesive can maintain the performance of the core component stable and extend the service life of the transformer.

[0098] Finally, the operation of solder resist adhesive is relatively simple, does not require complex equipment and technology, and is easy to implement on the production line. It simplifies the bonding process, reduces equipment investment costs, and improves process operability and economy. For example, in the production of small transformers, the use of solder resist adhesives can significantly simplify the bonding process, reduce equipment investment costs, and improve production efficiency. In addition, adhesives are usually made of environmentally friendly materials and have little impact on the environment. It reduces pollution to the environment, meets the requirements of green manufacturing, and improves the environmental performance of the product. The use of environmentally friendly solder resist adhesives can reduce the emission of harmful substances in the production process and meet the environmental protection standards of modern manufacturing.

[0099] In this embodiment, the first magnetic core and the second magnetic core are bonded by using solder resist as an adhesive; the solder resist includes at least EP3189 green glue. This adhesive has good insulation performance and mechanical strength, and can effectively improve the insulation performance and mechanical stability of the magnetic core assembly. At the same time, the rapid curing characteristics of the solder resist adhesive shorten the process time, reduce heat generation, simplify the process flow, and improve production efficiency and environmental protection performance. These improvement measures jointly improve the performance and reliability of the transformer core assembly and achieve efficient magnetic integration.

[0100] In some embodiments, if there are multiple middle columns, the bodies of the first magnetic core and the second magnetic core also include at least one third side column, and each third side column is arranged between two adjacent middle columns; the first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are determined as bonding areas, including: the first side column, the second side column, the third side column and the middle column of the first magnetic core and the second magnetic core are respectively determined as bonding areas, so as to use a preset adhesive to bond the first magnetic core and the second magnetic core through the bonding area; the solder resist includes at least EP3189 green glue.

[0101] In the case where there are multiple middle columns, the bodies of the first magnetic core and the second magnetic core further include at least one third side column. Each third side column is arranged between two adjacent middle columns. The first side column, the second side column, the third side column and the middle column of the first magnetic core and the second magnetic core are determined as bonding areas. These bonding areas are the parts of the magnetic core assembly that need to be bonded with emphasis. Use a marking tool (such as a pencil or a marker) to mark the bonding area on the surface of the magnetic core, including the first side column, the second side column, the third side column and the middle column. The marking should be accurate to facilitate subsequent operations. According to the characteristics of the magnetic core material and the bonding requirements, select a suitable adhesive (such as resin, polyurethane, etc.). Ensure that the adhesive has good fluidity and curing properties. Use a dispensing machine or a manual glue coating tool to evenly apply the adhesive to the marked bonding area. Dot coating, line coating or surface coating can be used to ensure that the adhesive covers the entire bonding area. Control the thickness of the glue coating to ensure that the adhesive forms a uniform thin layer in the bonding area without accumulation or leakage. The thickness is usually controlled between 0.1-0.3 mm. By adding bonding to the third side column, the mechanical strength of the core assembly is improved. The seismic resistance of the core assembly in high vibration and impact environments is enhanced, and the risk of core loosening and separation is reduced. For example, in high-frequency transformers, multi-point bonding can significantly improve the mechanical strength of the core assembly and ensure its stability in high vibration environments. At the same time, in high-voltage transformers, multi-point bonding can effectively prevent partial discharge and improve the insulation performance of the transformer.

[0102] For the multi-point bonding method, fixed parameters (such as bonding area, pressure, temperature, and time) can be set to ensure that the bonding effect is consistent each time. The controllability and standardization of the production process are improved, and product quality fluctuations caused by inconsistent bonding are reduced. For example, by setting fixed bonding parameters, consistent bonding effects can be maintained in different batches of core components, reducing product quality fluctuations caused by inconsistent bonding. The bonding area can also be adjusted according to different core designs and requirements to adapt to a variety of core structures. For example, in transformers of different models and specifications, the multi-point bonding method can flexibly adjust the bonding area to adapt to different core design requirements.

[0103] In this embodiment, the first side column, the second side column, the third side column and the middle column of the first magnetic core and the second magnetic core are determined as the bonding area, and a preset adhesive is used for multi-point bonding. This method significantly increases the bonding area, improves the bonding strength and mechanical stability, improves the insulation performance, and improves the production efficiency and the consistency and controllability of the process. The multi-point bonding method has high flexibility and versatility, is suitable for the design of a variety of magnetic core structures, and is an effective means to improve the performance of transformer magnetic core components.

[0104] In some embodiments, the magnetic core assembly also includes a mounting piece, and the mounting piece and the winding module both include multiple mounting holes; after the first magnetic core and the second magnetic core are bonded using a preset adhesive, it also includes: a fixed connection between the mounting piece, the first magnetic core, the second magnetic core and the winding module is achieved through the mounting holes connected to the winding module.

[0105] Both the mounting part and the winding module include multiple mounting holes. Check and clean these mounting holes to ensure that there are no impurities and residues. Mark the location of the mounting holes on the mounting part to ensure that they correspond to the location of the mounting holes on the winding module. Align the mounting part with the winding module to ensure that the mounting holes of the two are in the same position. Select screws or bolts of appropriate size and length to ensure that they can pass through the mounting holes and fix the mounting part and the winding module. Pass the screws or bolts through the mounting holes of the mounting part and the winding module in turn, ensuring that each mounting hole is closely aligned. Use appropriate tools (such as wrenches or screwdrivers) to tighten the screws or bolts one by one to ensure that the mounting part and the winding module are firmly connected. Confirm that the mounting holes of the mounting part and the winding module are fully aligned and the screws or bolts are correctly installed. Confirm that each screw or bolt is tightened in place and there is no looseness. A torque wrench can be used to ensure that the screws or bolts are tightened according to the specified torque. Fix the mounting part, the first core, the second core and the winding module as a whole through the mounting holes to ensure that the components are tightly connected. Check the fixing effect of the entire component to ensure that there is no looseness and offset. Tap and vibration tests can be performed to ensure stable connections between components.

[0106] The mounting hole connecting the mounting part to the winding module is used to achieve fixed connection between the mounting part, the first magnetic core, the second magnetic core and the winding module. This method significantly improves the fixing strength of the overall component, simplifies the installation process, facilitates maintenance and replacement, enhances stability, and improves the consistency and standardization of the production process. By optimizing the structural design, the compactness and space utilization of the overall component are improved, which is an effective means to improve the performance of the transformer core component.

[0107] The present application discloses a method for preparing a magnetic core for a transformer. The method first cleans the first magnetic core and the second magnetic core to remove impurities and oxide layers on their surfaces. This step is to ensure that the bonding surface is clean and flat, thereby improving the reliability and stability of the bonding. After the cleaning is completed, the winding module is placed on the first magnetic core / the second magnetic core, ensuring that the first accommodating cavity in the winding module is aligned with the middle column of the first magnetic core. The winding module is usually composed of multiple layers of insulating materials and wire windings, and its structure and position design can effectively reduce electromagnetic interference. The first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are determined as bonding areas. This is to ensure the bonding strength of the magnetic core at key positions, thereby improving the mechanical stability and electrical performance of the entire magnetic core assembly. At the same time, a preset resin material is used as an adhesive to bond the first magnetic core and the second magnetic core in the bonding area. The resin has good mechanical strength, high temperature resistance and insulation properties, and can effectively solve the problems existing in traditional bonding materials.

[0108] The method provided has at least the following beneficial effects

[0109] 1. Reduce heat generation: Compared with traditional solder and insulating glue, the curing process of resin generates less heat. This can effectively reduce the temperature rise caused by the thermal effect of the bonding material during the use of the transformer, thereby improving the thermal stability of the transformer.

[0110] 2. Shorten the curing time: The curing time of the resin is relatively short, and the bonding process can be completed in a shorter time. This is of great significance for improving production efficiency and reducing costs.

[0111] 3. Improve insulation performance: Resin has excellent insulation performance and can effectively prevent current leakage and short circuit. This not only improves the safety of the transformer, but also extends its service life.

[0112] 4. Enhanced mechanical strength: The high mechanical strength of the resin can provide good support and fixation in the bonding area, thereby improving the overall mechanical stability of the core assembly. This is especially important for the performance of the transformer in high vibration and shock environments.

[0113] 5. Improve the production process: This method improves the quality and reliability of bonding by cleaning the core surface in advance to ensure that the bonding area is clean and free of impurities. In addition, the placement and alignment process of the winding module is also more precise, which helps to reduce errors and defective product rates in production.

[0114] Please refer to Figure 8 , Figure 8 It is a schematic structural block diagram of a transformer provided in an embodiment of the present application. The provided transformer 100 includes at least one magnetic core component 10 provided in any embodiment of the present application.

[0115] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of various equivalent modifications or replacements within the technical scope disclosed in the present application, and these modifications or replacements should be included in the protection scope of the present application. Therefore, the protection scope of the present application shall be based on the protection scope of the claims.

Claims

1. A method for preparing a magnetic core component for a transformer, characterized in that: A magnetic core assembly for preparing a transformer, the magnetic core assembly comprising a first magnetic core, a second magnetic core and a winding module, the first magnetic core and the second magnetic core are both formed with a first side column, a second side column and at least one middle column, the winding module is formed with at least one first accommodating cavity, the winding module is arranged on the first magnetic core, each of the middle columns is arranged in the first accommodating cavity, and the second magnetic core is bonded to the first magnetic core toward the winding module; the method comprises: Cleaning the first magnetic core and the second magnetic core respectively to remove impurities and oxide layers of the first magnetic core and the second magnetic core; Placing the winding module on the cleaned first magnetic core or the second magnetic core; The first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are defined as bonding areas, and a preset adhesive is used to bond the first magnetic core and the second magnetic core through the bonding areas; wherein the adhesive is made of resin material.

2. The method according to claim 1, characterized in that The cleaning of the first magnetic core and the second magnetic core respectively comprises: The first magnetic core and the second magnetic core are cleaned respectively using a copper brush to roughen the surfaces of the first magnetic core and the second magnetic core and increase the contact area between the adhesive and the first magnetic core and the second magnetic core.

3. The method according to claim 1, characterized in that The step of bonding the first magnetic core and the second magnetic core via the bonding area using a preset adhesive comprises: The first magnetic core and the second magnetic core are bonded to each other via the bonding area using a solder resist composed of epoxy resin and curing agent; and / or the solder resist is green glue.

4. The method according to claim 1, characterized in that: If there are multiple middle pillars, the bodies of the first magnetic core and the second magnetic core each further include at least one third side pillar, and each of the third side pillars is disposed between two adjacent middle pillars; The step of determining the first side column, the second side column and the middle column of the first magnetic core and the second magnetic core as the bonding area comprises: The first side column, second side column, third side column and middle column of the first magnetic core and the second magnetic core are respectively determined as the bonding area, so as to use a preset adhesive to bond the first magnetic core and the second magnetic core through the bonding area; the solder resist includes at least EP3189 green glue.

5. The method according to claim 1, characterized in that The magnetic core assembly further includes a mounting member, and the mounting member and the winding module both include a plurality of mounting holes; after the first magnetic core and the second magnetic core are bonded together using a preset adhesive, the method further includes: The mounting member, the first magnetic core, the second magnetic core and the winding module are fixedly connected through the mounting hole of the mounting member communicating with the winding module.

6. A magnetic core assembly for a transformer, characterized in that: The magnetic core assembly comprises: A first magnetic core and a second magnetic core, wherein the bodies of the first magnetic core and the second magnetic core are both formed with a first side column, a second side column and at least one middle column; A winding module, wherein at least one first accommodating cavity is formed in the winding module, the winding module is arranged on the first magnetic core or the second magnetic core, and each of the middle columns is arranged in the first accommodating cavity; The first side column, the second side column and the middle column of the first magnetic core and the second magnetic core are bonding areas, and a preset adhesive is used to bond the first magnetic core and the second magnetic core through the bonding area; wherein the adhesive is made of resin material.

7. The magnetic core assembly according to claim 6, wherein the shape of the first accommodating cavity is adapted to the shape of the middle column; and / or, The shape of the center column is any one of circular, rectangular, elliptical and diamond.

8. The magnetic core assembly according to claim 6, characterized in that: If there are multiple middle columns, and the length of each middle column along the preset direction is greater than the preset length, a third side column is further formed on the body of the first magnetic core; Wherein, the preset direction is a direction along the first side column pointing toward the second side column.

9. The magnetic core assembly according to claim 8, characterized in that: The winding module further comprises: At least one second accommodating area, the shape of the second accommodating area is adapted to the shape of the third side pillars, and each of the third side pillars is arranged in the second accommodating area.

10. The magnetic core assembly according to claim 8, characterized in that: Each of the third side pillars and the middle pillar, the first side pillar and the second side pillar form the bonding area.

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