Transformer

Abstract

The invention relates to the technical field of electronic components, in particular to a transformer. The transformer comprises a framework, a coil winding and a first insulating layer, and the coil winding is wound on the framework around the axis of the framework; the coil winding comprises a primary winding and a secondary winding, the primary winding comprises a plurality of primary coils, and the secondary winding comprises a plurality of secondary coils; the primary coils and the secondary coils are alternately distributed in the radial direction of the framework, one secondary coil is arranged between every two adjacent primary coils, one primary coil is arranged between every two adjacent secondary coils, and first insulating layers are arranged between the primary coils and the secondary coils. The primary coil and the secondary coil are alternately arranged, so that the primary coil and the secondary coil are closer to each other in space, magnetic flux leakage is reduced due to alternate arrangement, energy loss is directly reduced due to reduction of leakage inductance, the magnetic flux coupling efficiency is remarkably improved, and the power transmission efficiency of the transformer is improved.

Description

Technical Field

[0001] This application relates to the field of electronic components technology, and more specifically, to a transformer. Background Technology

[0002] A transformer is a device that uses the principle of electromagnetic induction to change alternating current voltage. Its main components include a primary coil, a secondary coil, a frame, and a magnetic core. As a core component in electronic equipment, the transformer's main functions include voltage transformation, current transformation, impedance transformation, isolation, and voltage stabilization. Its performance directly affects the efficiency and stability of the equipment. To meet various voltage requirements, transformers typically have multiple windings. However, due to the small size and limited space of transformers, the winding arrangement can easily lead to increased leakage inductance, causing power loss and electromagnetic interference.

[0003] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this application, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0004] The purpose of this application is to provide a transformer that solves the technical problem in the related art where the winding arrangement in a limited space easily leads to an increase in leakage inductance.

[0005] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0006] This application provides a transformer, including: a frame, a coil winding, and a first insulating layer, wherein the coil winding is wound around the frame about the axis of the frame;

[0007] The coil winding includes a primary winding and a secondary winding. The primary winding includes multiple primary coils, and the secondary winding includes multiple secondary coils. The multiple primary coils and the multiple secondary coils are arranged alternately around the skeleton radially. A secondary coil is disposed between two adjacent primary coils, and a primary coil is disposed between two adjacent secondary coils. A first insulating layer is disposed between the primary coils and the secondary coils.

[0008] In some implementations, the transformer further includes a second insulating layer that encloses the coil winding.

[0009] In some implementations, the transformer further includes a circuit board, which is fixedly connected to the frame.

[0010] In some implementations, the transformer further includes lead pins fixed to the circuit board; each end of the primary coil is connected to one of the lead pins, and each end of the secondary coil is connected to one of the lead pins.

[0011] The skeleton is provided with multiple wire grooves, and the number of wire grooves is equal to the number of lead-out pins;

[0012] The partial structures of the primary coil and the secondary coil are respectively located in their respective slots.

[0013] In some implementations, the transformer further includes a magnetic core, which is fixedly connected to the frame; the second insulating layer also wraps around the magnetic core.

[0014] In some implementations, the skeleton is made of bakelite; the magnetic core is made of manganese-zinc ferrite.

[0015] In some implementations, the first insulating layer includes insulating tape.

[0016] In some implementations, the second insulating layer is an insulating varnish layer.

[0017] In some implementations, the circuit board is a rigid circuit board.

[0018] In some implementations, the number of primary coils is 5 and the number of secondary coils is 5.

[0019] The main advantages of the transformer provided in this application are:

[0020] This application employs an alternating arrangement of the primary and secondary coils, bringing them closer together in space. This alternating arrangement reduces magnetic flux leakage, and the reduction in leakage inductance directly reduces energy loss, significantly improving magnetic flux coupling efficiency and enhancing the transformer's power transmission efficiency. The alternating arrangement also optimizes the magnetic field distribution, reducing external electromagnetic interference caused by leakage flux. In high-frequency applications, this effectively reduces electromagnetic interference to surrounding circuits, improving overall system stability. The alternating arrangement fully utilizes the radial space of the frame, reducing space waste, and this design allows for multi-winding configurations within a limited volume to meet various voltage requirements. Furthermore, the first insulation layer between the primary and secondary coils effectively isolates the high and low voltage sides, preventing electrical breakdown or short circuits and improving the transformer's safety and reliability. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a front view of the transformer provided in the embodiment of this application;

[0023] Figure 2 This is a right view of the transformer provided in an embodiment of this application;

[0024] Figure 3 This is a bottom view of the transformer provided in the embodiment of this application;

[0025] Figure 4 This is a radial cross-sectional schematic diagram of the coil winding and the first insulation layer wound on the skeleton according to an embodiment of this application;

[0026] Figure 5 yes Figure 4 A magnified schematic diagram of the local structure at point A;

[0027] Figure 6 This is a schematic diagram of the principle structure of the transformer provided in the embodiment of this application.

[0028] Explanation of key figure labels:

[0029] 100. Skeleton; 101. Coil winding; 102. First insulation layer; 103. Primary coil; 104. Secondary coil; 105. Shaft; 106. Circuit board; 107. Lead pin; 108. Wire groove; 109. Magnetic core. Detailed Implementation

[0030] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0031] Combination Figure 1 and Figure 5As shown, this application embodiment provides a transformer, including: a frame 100, a coil winding 101, and a first insulating layer 102. The coil winding 101 is wound around the axis of the frame 100. The coil winding 101 includes a primary winding and a secondary winding. The primary winding includes a plurality of primary coils 103, and the secondary winding includes a plurality of secondary coils 104. The plurality of primary coils 103 and the plurality of secondary coils 104 are alternately distributed radially around the frame 100. A secondary coil 104 is disposed between two adjacent primary coils 103, and a primary coil 103 is disposed between two adjacent secondary coils 104. The first insulating layer 102 is disposed between the primary coil 103 and the secondary coil 104.

[0032] The transformer provided in this embodiment alternately arranges the primary coil 103 and the secondary coil 104, bringing them closer together in space. This alternating arrangement reduces magnetic flux leakage, and the reduction in leakage inductance directly reduces energy loss, significantly improving magnetic flux coupling efficiency and enhancing the transformer's power transmission efficiency. The alternating arrangement also optimizes the magnetic field distribution, reducing external electromagnetic interference caused by leakage flux. In high-frequency applications, this effectively reduces electromagnetic interference to surrounding circuits, improving overall system stability. The alternating arrangement fully utilizes the radial space of the frame 100, reducing space waste. Furthermore, this design allows for multi-winding configurations within a limited volume, meeting various voltage requirements. The first insulation layer 102 between the primary coil 103 and the secondary coil 104 effectively isolates the high and low voltage sides, preventing electrical breakdown or short circuits and improving the transformer's safety and reliability.

[0033] Combination Figure 1 , Figure 2 and Figure 4As shown, in some embodiments, the frame 100 may have a shaft 105, which may be cylindrical; the axis of the frame 100 is the central axis of the shaft 105; the radial direction of the frame 100 is the radial direction of the shaft 105. The coil winding 101 is wound around the shaft 105, that is, the primary coil 103 is wound around the axis of the shaft 105, and the secondary coil 104 is wound around the axis of the shaft 105. Viewed radially from the shaft 105, multiple primary coils 103 and multiple secondary coils 104 are alternately distributed, thereby achieving a fully interleaved winding method for the coil winding 101 on the frame 100; and the alternating distribution of multiple primary coils 103 and multiple secondary coils 104 means that, viewed radially from the shaft 105, one primary coil 103, one secondary coil 104, one primary coil 103, one secondary coil 104, ..., continuously alternating in this manner. To achieve isolation between the primary coil 103 and the secondary coil 104, a first insulating layer 102 is provided between adjacent primary coils 103 and secondary coils 104. Exemplarily, the innermost layer of the coil winding 101 is the primary coil 103, meaning the primary coil 103 is wound first onto the shaft 105. It should be noted that in some other possible embodiments, the innermost layer may also be the secondary coil 104; the specific configuration can be determined according to actual circumstances.

[0034] In some embodiments, the transformer is a transformer with multiple coils, that is, the transformer has multiple primary coils and multiple secondary coils 104; the number of primary coils 103 is equal to the number of secondary coils 104, for example, there are 5 primary coils 103 and 5 secondary coils 104; this can meet various voltage requirements. See also Figure 6 As shown, for ease of explanation, the five primary coils 103 can be represented as N1, N2, N3, N4, and N5; and the five secondary coils 104 can be represented as N6, N7, N8, N9, and N10; the two pins corresponding to N1 are 1 and 11; the two pins corresponding to N2 are 2 and 12; the two pins corresponding to N3 are 3 and 13; the two pins corresponding to N4 are 4 and 14; the two pins corresponding to N5 are 5 and 15; the two pins corresponding to N6 are 6 and 16; the two pins corresponding to N7 are 7 and 17; the two pins corresponding to N8 are 8 and 18; the two pins corresponding to N9 are 9 and 19; and the two pins corresponding to N10 are 10 and 20. Figure 6 In the diagram, the black dots represent the starting and ending points.

[0035] It is understandable that when the number of primary coils 103 is equal to the number of secondary coils 104, the number of primary coils 103 is not limited to 5, but can also be 2, 3, 6 or 7, etc.

[0036] It should be noted that in some other possible implementations, the number of primary coils 103 and the number of secondary coils 104 may not be equal. For example, the number of primary coils 103 may be greater than the number of secondary coils 104, or the number of primary coils 103 may be less than the number of secondary coils 104.

[0037] In some embodiments, the number of first insulating layers 102 between the primary coil 103 and the secondary coil 104 can be one or more, such as two or three, and this application does not make a specific limitation.

[0038] In some embodiments, the first insulating layer 102 includes insulating tape. Exemplarily, the first insulating layer 102 may consist only of insulating tape, made of polyimide or polyester film. This effectively isolates the high voltage difference between the primary coil 103 and the secondary coil 104, preventing electrical breakdown or short circuits. Furthermore, due to the flexibility and adhesiveness of the insulating tape, it is easy to wrap between the primary and secondary coils 104 or between sub-coils, adapting to complex winding structures, thereby reducing production difficulty and improving manufacturing efficiency. The tape's flexibility also allows it to tightly adhere to irregular coil surfaces, ensuring uniform insulation coverage and reducing space waste. Moreover, the insulating tape is thin, occupying little space while maintaining insulation performance. When polyimide tape is used, it also has excellent high-temperature resistance. It should be noted that in some other possible embodiments, the first insulating layer 102 may also include insulating tape and an insulating varnish layer. The insulating varnish layer, in conjunction with the insulating tape, improves the high voltage withstand capability between the transformer windings.

[0039] In some embodiments, the transformer further includes a second insulating layer (not shown) that wraps around the coil winding 101, thereby improving the high voltage withstand capability between the transformer windings; in addition, the second insulating layer wraps around the entire coil winding 101, providing an additional external insulation barrier for the primary and secondary coils 104, preventing the coil from making electrical contact or breaking down with external conductors (such as other circuit elements); furthermore, the second insulating layer seals the entire coil winding 101, preventing moisture, dust or other contaminants from entering the coil, reducing the risk of insulation failure or corrosion caused by environmental factors.

[0040] In some embodiments, the second insulating layer is an insulating varnish layer. The second insulating layer, formed by curing the insulating varnish, can improve the high-voltage withstand capability between the transformer windings. For example, the insulating varnish can be epoxy resin or polyurethane varnish. The insulating varnish can be formed into a uniform, seamless insulating varnish layer through dip coating, spraying, or vacuum potting processes, covering the primary coil 103 and secondary coil 104 of the coil winding 101, significantly improving electrical safety. In addition, the insulating varnish layer forms a dense protective film, effectively preventing moisture, dust, or other contaminants from entering the coil, reducing the risk of insulation failure, corrosion, or aging caused by environmental factors. Finally, the insulating varnish layer, combined with the first insulating layer 102, can improve the overall structural integrity of the coil winding 101 and reduce the risk of failure caused by mechanical stress.

[0041] In some embodiments, the transformer further includes a circuit board 106, which is fixedly connected to the frame 100, thereby improving the transformer's resistance to vibration and impact. For example, the circuit board 106 is bonded to the frame 100.

[0042] Combination Figures 1 to 3 As shown, in some embodiments, the transformer further includes lead pins 107, which are fixed to the circuit board 106. Each end of the primary coil 103 is connected to a lead pin 107, and each end of the secondary coil 104 is connected to a lead pin 107. The frame 100 is provided with multiple slots 108, the number of which is equal to the number of lead pins 107. Parts of the primary coil 103 and the secondary coil 104 are located in their respective slots 108. This facilitates the connection between the transformer and other electrical components. For example, both ends of the primary coil 103 and the secondary coil 104 are lead ends, which are fixed to the lead pins 107 by soldering. The lead pins 107 are made of copper or tin-plated copper. The portions of the primary coil 103 and the secondary coil 104 located in the slots 108 are close to the lead ends. This ensures that each lead end corresponds to a slot 108 and a lead pin 107. This design standardizes the lead-out path, reduces wiring confusion, and improves assembly accuracy. In addition, the slots 108 also provide physical isolation and fixation for the coils, preventing winding misalignment or overlap, which helps optimize magnetic flux coupling and reduce leakage inductance.

[0043] It should be noted that in some other possible implementations, at least one primary coil 103 may include multiple sub-coils distributed axially. For example, it may include two sub-coils, each with a lead end at each end, which is connected to a pin 107. Thus, one primary coil 103 has four leads, each connected to a pin 107. This divides the primary coil 103 into multiple sub-coils distributed axially, allowing for more flexible winding configurations. Each sub-coil can independently control current or voltage to adapt to different circuit requirements, such as supporting multiple voltage outputs or parallel / series combinations. The two leads of each sub-coil provide more connection points, facilitating flexible wiring of external circuits. For example, series, parallel, or tap outputs can be achieved through different combinations of leads, meeting complex power management needs. The axial distribution of multiple sub-coils results in a more uniform current distribution in the primary coil 103, leading to a more even heat distribution in the axial direction of the frame 100, reducing the risk of heat concentration, and improving the thermal stability and long-term operational reliability of the transformer. Based on the radially alternating arrangement of the primary and secondary coils 104, the axially distributed sub-coils further optimize the magnetic flux distribution, reduce uncoupled leakage flux, and lower leakage inductance, thereby reducing power loss and electromagnetic interference.

[0044] In some embodiments, both the primary coil 103 and the secondary coil 104 are made of enameled copper wire with polyesterimide insulating varnish and a temperature rating of 220°C. This enameled copper wire has good abrasion resistance, chemical resistance, and high safety withstand voltage performance, and exhibits high stability in humid, salt spray, and moldy environments. It should be noted that the lead ends of the primary coil 103 and the secondary coil 104 can be sleeved in a tubing made of insulating material such as polyimide, silicone, or polytetrafluoroethylene. The tubing provides additional insulation protection for the lead ends of the primary coil 103 and the secondary coil 104, preventing accidental contact or short circuits between the lead ends and the frame 100, the magnetic core 109, other lead ends, or the circuit board 106.

[0045] See Figure 1 and Figure 2 As shown, in some embodiments, the transformer further includes a magnetic core 109, which is fixedly connected to the frame 100. This enhances the mechanical strength of the transformer and prevents components from loosening or shifting during vibration, impact, or transportation. A second insulating layer also wraps around the magnetic core 109, which strengthens the electrical isolation between the magnetic core 109 and the coils, and between the magnetic core 109 and external conductors, preventing high-voltage breakdown or short circuits. It also improves the transformer's resistance to vibration, impact, and tensile stress. Exemplarily, the magnetic core 109 and the frame 100 can be fixedly connected by snap-fit, bolts, or adhesive.

[0046] In some embodiments, the skeleton 100 is made of bakelite; the magnetic core 109 is made of manganese-zinc ferrite, giving the magnetic core 109 a high Curie temperature and good environmental adaptability. For example, the skeleton 100 can be made of high-temperature resistant bakelite, which needs to have a melting temperature of 410°C and strong chemical resistance. For instance, bakelite can be polyimide-modified phenolic resin or aromatic phenolic resin.

[0047] In some embodiments, circuit board 106 is a rigid circuit board. For example, the rigid circuit board is a printed circuit board (PCB), and the material of the printed circuit board can be a high-temperature resistant fiberglass board. The melting temperature of the high-temperature resistant fiberglass board can reach 400°C, which enables the transformer to operate for a long time in a high-temperature, high-humidity, and moldy environment.

[0048] In summary, the transformer provided in this application has advantages such as stable structure, vibration resistance, impact resistance, tensile strength, high withstand voltage, small size, high winding integration, flexible transformation, and strong environmental adaptability. This transformer can achieve a reasonable arrangement of multiple windings within a limited space, with low leakage inductance, good insulation between windings, and can withstand a high withstand voltage of 1500V. It also meets reliable operation requirements under extreme climatic conditions (-55℃ to 150℃) and has excellent heat dissipation. The selected materials have good resistance to moisture, mildew, salt spray, and damp heat, thus improving the overall reliability of the transformer when applied to mobile equipment.

[0049] It should be understood that, in the embodiments of this application, unless otherwise expressly specified and limited, the terms "connection," "fixed connection," "contact," etc., should be interpreted broadly. Those skilled in the art can understand the specific meanings of the various terms in the embodiments of this application according to the specific circumstances.

[0050] For example, the "connection" can be a fixed connection, a rotating connection, a flexible connection, a sliding connection, a one-piece molding, an electrical connection, a contact connection, or other connection methods; it can be a direct connection, or an indirect connection through an intermediate medium, or a connection within two components or an interaction between two components.

[0051] For example, a "fixed connection" can be a component that can be directly or indirectly fixedly connected to another component; a fixed connection can include mechanical connection, welding, bonding or integral molding, etc., wherein mechanical connection can include riveting, bolting, threaded connection, keying, snap-fit ​​connection, locking connection, plugging, etc., and bonding can include adhesive bonding and solvent bonding, etc.

[0052] It should also be understood that the “parallel” or “perpendicular” described in the embodiments of this application can be understood as “approximately parallel” or “approximately perpendicular”.

[0053] It should also be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Features specified as "first" or "second" may explicitly or implicitly include one or more of that feature.

[0054] In the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature and the second feature are in direct contact, or that the first feature and the second feature are in indirect contact through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0055] It should also be understood that the terms “length,” “width,” “up,” “down,” “front,” “back,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” etc., indicate the orientation or positional relationship (if any) based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0056] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of protection of the claims. In conclusion, the above description is merely a preferred embodiment of the technical solution of this application and is not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A transformer, characterized in that, include: A frame, a coil winding, and a first insulating layer, wherein the coil winding is wound around the frame about the axis of the frame; The coil winding includes a primary winding and a secondary winding. The primary winding includes multiple primary coils, and the secondary winding includes multiple secondary coils. The multiple primary coils and the multiple secondary coils are arranged alternately around the skeleton radially. A secondary coil is disposed between two adjacent primary coils, and a primary coil is disposed between two adjacent secondary coils. A first insulating layer is disposed between the primary coils and the secondary coils.

2. The transformer as described in claim 1, characterized in that, The transformer also includes a second insulating layer that wraps around the coil winding.

3. The transformer as described in claim 2, characterized in that, The transformer also includes a circuit board, which is fixedly connected to the frame.

4. The transformer as described in claim 3, characterized in that, The transformer also includes lead pins, which are fixed to the circuit board; each end of the primary coil is connected to one of the lead pins, and each end of the secondary coil is connected to one of the lead pins. The skeleton is provided with multiple wire grooves, and the number of wire grooves is equal to the number of lead-out pins; The partial structures of the primary coil and the secondary coil are respectively located in their respective slots.

5. The transformer as described in any one of claims 2-4, characterized in that, The transformer also includes a magnetic core, which is fixedly connected to the frame; the second insulating layer also wraps around the magnetic core.

6. The transformer as described in claim 5, characterized in that, The skeleton is made of bakelite; the magnetic core is made of manganese-zinc ferrite.

7. The transformer as described in any one of claims 1-4, characterized in that, The first insulating layer includes insulating tape.

8. The transformer as described in claim 2, characterized in that, The second insulating layer is an insulating varnish layer.

9. The transformer as described in claim 3 or 4, characterized in that, The circuit board is a rigid circuit board.

10. The transformer as described in any one of claims 1-4, characterized in that, The number of primary coils is 5, and the number of secondary coils is 5.

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