Industrial power transformer stable in structure and efficient in heat dissipation
By using a multi-air gap structure and an insulating cover design, the problems of increased leakage flux and localized overheating in traditional transformers in complex environments are solved, achieving stable and efficient power conversion and heat dissipation.
Patent Information
- Application Number
- CN202511193915.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-25
- Publication Date
- 2025-11-11
AI Technical Summary
Traditional industrial power transformers suffer from problems such as increased leakage flux, increased electromagnetic radiation, high risk of magnetic saturation, and low conversion efficiency when operating in environments with high-frequency vibration, high temperature, and strong electromagnetic interference.
The design employs a multi-air gap structure, including a first air gap and a second air gap, and combines an insulating cover, a rectangular shield, and thermally conductive materials to optimize the magnetic field distribution and heat dissipation path.
It effectively reduces magnetic leakage, provides a uniform magnetic field distribution, reduces local overheating, improves power conversion efficiency and equipment stability, and enhances electromagnetic compatibility.
Smart Images
Figure CN120933045A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of transformer technology, and specifically to an industrial power transformer with a robust structure and efficient heat dissipation. Background Technology
[0002] As a core component of power conversion systems, industrial power transformers need to operate stably for extended periods in complex environments characterized by high-frequency vibration, high temperatures, and strong electromagnetic interference. Traditional transformers often employ a single air-gap structure. When the air gap width is too large, leakage flux increases significantly, leading to enhanced electromagnetic radiation and interference with surrounding equipment. Conversely, when the air gap is too small, the risk of magnetic saturation increases, affecting conversion efficiency. Furthermore, a single air gap is prone to localized overheating due to concentrated magnetic fields. Summary of the Invention
[0003] The purpose of this invention is to address the aforementioned shortcomings in the prior art by providing an industrial power transformer with a robust structure and efficient heat dissipation.
[0004] The objective of this invention is achieved through the following technical solution: a robust and efficient industrial power transformer, comprising a base, a lower magnetic core, an upper magnetic core, a middle magnetic column, and an air gap plate; The lower magnetic core is located at the top of the base; a lower magnetic column is located in the middle of the lower magnetic core; the upper magnetic core is located at the top of the lower magnetic core; an upper magnetic column is located in the middle of the upper magnetic core; the upper magnetic column and the lower magnetic column are directly opposite each other; an air gap plate is located at the top of the lower magnetic column; a middle magnetic column is located at the top of the air gap plate; the upper magnetic core is located at the top of the middle magnetic column; an air gap through hole is provided through the air gap plate; a first air gap is formed between the bottom of the middle magnetic column, the air gap through hole, and the top of the lower magnetic column; a second air gap is formed between the top of the middle magnetic column and the bottom of the lower magnetic column. The lower magnetic core, the middle magnetic column, and the upper magnetic core are all wound with windings.
[0005] The present invention is further configured such that the structurally robust and heat-dissipating industrial power transformer also includes an insulating cover; the insulating cover is fitted over the lower magnetic core, the air gap plate, the intermediate magnetic column and the upper magnetic core; the winding is wound around the insulating cover.
[0006] The present invention is further configured such that the upper magnetic column, the lower magnetic column, and the middle magnetic column are all cylindrical; and the air gap plate is annular.
[0007] The present invention is further configured such that the winding includes a plurality of primary conductor coils and a plurality of secondary flat coils arranged in a vertical direction.
[0008] The present invention is further configured such that polyimide films are provided on both the upper and lower sides of the primary conductor coil.
[0009] The present invention is further configured such that: the top of the upper magnetic core is provided with an upper cover plate; the bottom of the upper cover plate is provided with a secondary circuit board along the vertical direction; the base is provided with external pins; the external pins are connected to the secondary circuit board; the secondary flat coil is provided with secondary pins; the secondary pins are connected to the secondary circuit board.
[0010] The present invention is further configured such that the structurally robust and heat-dissipating industrial power transformer also includes a rectangular shield; the rectangular shield is sleeved on the outside of the upper magnetic core and the lower magnetic core; the base is disposed at the bottom of the rectangular shield; and the upper cover is disposed at the top of the rectangular shield.
[0011] The present invention is further configured such that a locking block is provided on the top of the secondary circuit board; and a locking groove is provided on the upper cover plate to cooperate with the locking block.
[0012] The present invention is further configured such that a bracket is provided on the inner side of the secondary circuit board; a U-shaped frame is provided on the inner side of the bracket; and an adhesive channel is formed between the base, the bracket and the U-shaped frame.
[0013] The present invention is further configured such that the base is provided with a grounding pin and a primary pin; the primary conductor coil is connected to the primary pin.
[0014] The beneficial effects of the present invention are as follows: By dividing a single air gap into a first air gap and a second air gap, the overall magnetic field distribution is more uniform while the total air gap thickness remains unchanged, effectively reducing the leakage magnetic field. Furthermore, the segmented design of the air gap reduces local overheating caused by magnetic field concentration, effectively improving the overall heat dissipation effect. Attached Figure Description
[0015] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a structural schematic diagram from another perspective of the present invention; Figure 3 This is a cross-sectional view of the present invention; Figure 4 This is an exploded view of the structure of the present invention; Figure 5 This is an exploded view of the structure of the upper magnetic core, middle magnetic column, air gap plate and lower magnetic core of the present invention. The components are as follows: 1. Base; 11. External pin; 12. Ground pin; 13. Primary pin; 2. Lower magnetic core; 21. Lower magnetic post; 3. Upper magnetic core; 31. Upper magnetic post; 4. Middle magnetic post; 41. Air gap plate; 42. Air gap through hole; 43. First air gap; 44. Second air gap; 5. Insulating cover; 51. Primary conductor coil; 52. Secondary flat coil; 53. Polyimide film; 54. Secondary pin; 6. Top cover plate; 61. Slot; 7. Secondary circuit board; 71. Card block; 72. Bracket; 73. U-shaped frame; 8. Rectangular shield; 9. Potting channel. Detailed Implementation
[0016] The present invention will be further described in conjunction with the following embodiments.
[0017] Depend on Figures 1 to 5 As can be seen, the industrial power transformer with a stable structure and efficient heat dissipation described in this embodiment includes a base 1, a lower magnetic core 2, an upper magnetic core 3, a middle magnetic column 4, and an air gap plate 41. The lower magnetic core 2 is disposed on the top of the base 1; a lower magnetic column 21 is disposed in the middle of the lower magnetic core 2; an upper magnetic core 3 is disposed on the top of the lower magnetic core 2; an upper magnetic column 31 is disposed in the middle of the upper magnetic core 3; the upper magnetic column 31 and the lower magnetic column 21 are arranged opposite each other; an air gap plate 41 is disposed on the top of the lower magnetic column 21; an intermediate magnetic column 4 is disposed on the top of the air gap plate 41; the upper magnetic core 3 is disposed on the top of the intermediate magnetic column 4; an air gap through hole 42 is provided through the air gap plate 41; a first air gap 43 is formed between the bottom of the intermediate magnetic column 4, the air gap through hole 42 and the top of the lower magnetic column 21; a second air gap 44 is formed between the top of the intermediate magnetic column 4 and the bottom of the lower magnetic column 21. The lower magnetic core 2, the middle magnetic column 4, and the upper magnetic core 3 are all wound with windings.
[0018] Specifically, the industrial power transformer with a robust structure and efficient heat dissipation described in this embodiment divides the air gap into a first air gap 43 and a second air gap 44, making the magnetic field distribution in the magnetic circuit more dispersed and avoiding the problem of excessive magnetic field concentration in the traditional single air gap structure. In addition, this design can effectively reduce magnetic leakage while ensuring that the total air gap thickness remains unchanged, and at the same time make the heat distribution more uniform, providing favorable conditions for subsequent heat dissipation. Secondly, the winding is wound outside the magnetic core, which can fully couple with the magnetic circuit and improve the power conversion efficiency.
[0019] This embodiment describes a robust and efficient heat dissipation industrial power transformer, which further includes an insulating cover 5. The insulating cover 5 is fitted over the lower magnetic core 2, the air gap plate 41, the intermediate magnetic column 4, and the upper magnetic core 3. The windings are wound around the insulating cover 5. Specifically, the insulating cover 5 is made of a material with good insulation performance and high temperature resistance, such as FR-4 epoxy board. The insulating cover 5 can isolate the lower magnetic core 2, the intermediate magnetic column 4, and the upper magnetic core 3 from the windings, effectively preventing electrical short circuits between the lower magnetic core 2, the intermediate magnetic column 4, and the upper magnetic core 3 and the windings, thus improving the insulation reliability of the transformer. At the same time, the gaps formed between the insulating cover 5 and the lower magnetic core 2, the intermediate magnetic column 4, the upper magnetic core 3, and the windings can serve as heat transfer channels, which helps the windings dissipate heat.
[0020] This embodiment describes a robust and efficiently heat-dissipating industrial power transformer. The upper magnetic column 31, lower magnetic column 21, and intermediate magnetic column 4 are all cylindrical; the air gap plate 41 is annular. Specifically, the cylindrical upper magnetic column 31, lower magnetic column 21, and intermediate magnetic column 4 ensure a uniform radial distribution of the magnetic field, reducing magnetic field losses at corners and improving the utilization rate of the magnetic circuit. Furthermore, the annular air gap plate 41, in conjunction with the cylindrical magnetic columns, ensures the uniformity of the first air gap 43 and the second air gap 44, preventing magnetic field distortion caused by uneven air gaps, thereby ensuring the stability of the transformer's performance. In addition, this shape design facilitates processing and assembly, reducing production difficulty.
[0021] This embodiment describes a robust and efficiently heat-dissipating industrial power transformer. The windings include multiple primary conductor coils 51 and multiple secondary flat coils 52 arranged vertically. Specifically, the primary conductor coils 51 are wound with multi-strand wire, effectively reducing the skin effect and high-frequency losses, making them suitable for high-voltage, low-current primary circuits. The secondary flat coils 52 use flat conductors, increasing the heat dissipation area and facilitating heat dissipation, better meeting the needs of low-voltage, high-current secondary circuits. Furthermore, the vertical arrangement of the windings ensures tighter coupling between the primary conductor coils 51 and the secondary flat coils 52, improving energy conversion efficiency and facilitating winding arrangement and fixation.
[0022] This embodiment describes a robust and efficient heat dissipation industrial power transformer, in which polyimide films 53 are provided on both the upper and lower sides of the primary conductor coil 51. Specifically, the polyimide films 53 have excellent high-temperature resistance and insulation properties. Their placement on the upper and lower sides of the primary conductor coil 51 further strengthens the insulation between the primary conductor coils 51 and between the primary conductor coil 51 and the secondary flat coil 52, preventing inter-turn or inter-layer short circuits. Simultaneously, the polyimide films 53 can also buffer the stress on the windings under vibration, protecting the integrity of the winding structure.
[0023] This embodiment describes a robust and efficient heat dissipation industrial power transformer. The upper magnetic core 3 has an upper cover plate 6 on its top. A secondary circuit board 7 is vertically positioned at the bottom of the upper cover plate 6. The base 1 has external pins 11 connected to the secondary circuit board 7. The secondary flat coil 52 has secondary pins 54 connected to the secondary circuit board 7. Specifically, the upper cover plate 6 is made of aluminum. It not only protects the top of the upper magnetic core 3 but also serves as a heat dissipation component, conducting heat away from the upper magnetic core 3. Furthermore, the secondary circuit board 7 provides a convenient connection carrier for the output of the secondary flat coil 52. The connection between the secondary pins 54 and the secondary circuit board 7, as well as the connection between the external pins 11 and the secondary circuit board 7, achieves a modular design for the secondary output, facilitating connection to external circuits and improving assembly convenience and flexibility.
[0024] This embodiment describes a robust and efficiently heat-dissipating industrial power transformer. The transformer further includes a rectangular shield 8, which is fitted over the upper magnetic core 3 and the lower magnetic core 2. A base 1 is located at the bottom of the rectangular shield 8, and an upper cover plate 6 is located at the top of the rectangular shield 8. Specifically, the rectangular shield 8 is made of copper foil, which effectively absorbs and shields electromagnetic radiation leaking from the magnetic core, reducing electromagnetic interference from the transformer to surrounding precision equipment and improving the electromagnetic compatibility of the equipment. Simultaneously, the rectangular shield 8 encloses core components such as the upper magnetic core 3 and the lower magnetic core 2, providing some protection to the internal structure and enhancing the overall structural strength of the transformer.
[0025] This embodiment describes a robust and efficient heat dissipation industrial power transformer. The secondary circuit board 7 has a locking block 71 on its top; the upper cover plate 6 has a slot 61 that mates with the locking block 71. Specifically, the mating structure of the locking block 71 and the slot 61 achieves precise positioning and a secure connection between the secondary circuit board 7 and the upper cover plate 6, preventing displacement or loosening of the secondary circuit board 7 when the transformer is subjected to vibration or impact. This ensures the reliability of the secondary circuit connection, and the connection method is simple, convenient, and easy to assemble and maintain.
[0026] This embodiment describes a robust and efficient industrial power transformer with a secondary circuit board 7. The inner side of the secondary circuit board 7 is provided with a support 72; the inner side of the support 72 is provided with a U-shaped frame 73; and a potting channel 9 is formed between the base 1, the support 72, and the U-shaped frame 73. Specifically, the support 72 and the U-shaped frame 73 provide support and fixation for the secondary circuit board 7 and the windings, enhancing the stability of the transformer's internal structure. Furthermore, thermally conductive insulating adhesive can be injected into the potting channel 9, which, after curing, firmly bonds the base 1, support 72, and U-shaped frame 73 together, further improving the overall structural stability. Simultaneously, the thermally conductive insulating adhesive also improves heat conduction efficiency, transferring heat from the windings and core to the base 1 more quickly, enhancing heat dissipation.
[0027] This embodiment describes a robust and efficiently heat-dissipating industrial power transformer. The base 1 is equipped with a grounding pin 12 and a primary pin 13. The primary conductor coil 51 is connected to the primary pin 13. Specifically, the primary pin 13 provides an interface for connecting the primary conductor coil 51 to an external power source, ensuring normal access to the primary circuit. The grounding pin 12 conducts static electricity and leakage current from inside the transformer to the ground, improving equipment safety and also helping to reduce electromagnetic interference and enhance the transformer's operational stability.
[0028] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.
Claims
1. An industrial power transformer with a robust structure and efficient heat dissipation, characterized in that: It includes a base (1), a lower magnetic core (2), an upper magnetic core (3), a middle magnetic column (4), and an air gap plate (41); The lower magnetic core (2) is located at the top of the base (1); a lower magnetic column (21) is located in the middle of the lower magnetic core (2); an upper magnetic core (3) is located at the top of the lower magnetic core (2); an upper magnetic column (31) is located in the middle of the upper magnetic core (3); the upper magnetic column (31) and the lower magnetic column (21) are arranged opposite each other; an air gap plate (41) is located at the top of the lower magnetic column (21); an intermediate magnetic column (4) is located at the top of the air gap plate (41); the upper magnetic core (3) is located at the top of the intermediate magnetic column (4); an air gap through hole (42) is provided through the air gap plate (41); a first air gap (43) is formed between the bottom of the intermediate magnetic column (4), the air gap through hole (42), and the top of the lower magnetic column (21); a second air gap (44) is formed between the top of the intermediate magnetic column (4) and the bottom of the lower magnetic column (21). The lower magnetic core (2), the middle magnetic column (4) and the upper magnetic core (3) are all wound with windings.
2. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 1, characterized in that: The industrial power transformer with a robust structure and efficient heat dissipation also includes an insulating cover (5); the insulating cover (5) is fitted over the lower magnetic core (2), the air gap plate (41), the intermediate magnetic column (4) and the upper magnetic core (3); the winding is wound around the insulating cover (5).
3. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 1, characterized in that: The upper magnetic column (31), lower magnetic column (21) and middle magnetic column (4) are all cylindrical; the air gap plate (41) is annular.
4. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 1, characterized in that: The winding includes a plurality of primary conductor coils (51) arranged in a vertical direction and a plurality of secondary flat coils (52).
5. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 4, characterized in that: The primary conductor coil (51) is provided with polyimide film (53) on both the upper and lower sides.
6. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 4, characterized in that: The top of the upper magnetic core (3) is provided with an upper cover plate (6); the bottom of the upper cover plate (6) is provided with a secondary circuit board (7) in the vertical direction; the base (1) is provided with an external pin (11); the external pin (11) is connected to the secondary circuit board (7); the secondary flat coil (52) is provided with a secondary pin (54); the secondary pin (54) is connected to the secondary circuit board (7).
7. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 6, characterized in that: The industrial power transformer with a stable structure and efficient heat dissipation also includes a rectangular shield (8); the rectangular shield (8) is sleeved outside the upper magnetic core (3) and the lower magnetic core (2); the base (1) is located at the bottom of the rectangular shield (8); and the upper cover plate (6) is located at the top of the rectangular shield (8).
8. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 6, characterized in that: The secondary circuit board (7) has a locking block (71) on its top; the upper cover plate (6) has a slot (61) that cooperates with the locking block (71).
9. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 6, characterized in that: The secondary circuit board (7) has a bracket (72) on its inner side; the bracket (72) has a U-shaped frame (73) on its inner side; and a potting channel (9) is formed between the base (1), the bracket (72) and the U-shaped frame (73).
10. The industrial power transformer with a robust structure and efficient heat dissipation as described in claim 4, characterized in that: The base (1) is provided with a grounding pin (12) and a primary pin (13); the primary conductor coil (51) is connected to the primary pin (13).