High-frequency transformer

Abstract

The invention relates to the technical field of transformers, in particular to a high-frequency transformer which comprises a base, magnetic cores, a framework, a coil, adhesive tape and a temperature sensing wire, baffles are arranged at the front end and the rear end of the framework, a winding groove is formed in the middle of the framework, a mounting groove is formed in the framework, the magnetic cores are opposite pairwise and inserted into the mounting groove of the framework, the coil is wound on the winding groove of the framework, and the adhesive tape is of a double-layer structure. Comprising an inner adhesive tape and an outer adhesive tape, the inner adhesive tape wraps the two opposite magnetic cores, the outer adhesive tape wraps the inner adhesive tape, one end of the coil is connected with the temperature sensing wire, the other end of the coil is connected with the base, and the base is adhered to the magnetic cores. The adhesive tape of the high-frequency transformer comprises the inner adhesive tape and the outer adhesive tape, the inner adhesive tape wraps the outer sides of the two opposite magnetic cores, the outer adhesive tape wraps the outer side of the inner adhesive tape, the inner adhesive tape and the outer adhesive tape play a role in insulation and isolation and further play a role in sealing and shielding, and it is guaranteed that the shielding effect of the high-frequency transformer is good; through mutual cooperation of all parts, mutual conversion of electromagnetic energy is realized, and power conversion application with output power of 1-6KW is satisfied.

Description

Technical Field

[0001] This invention relates to the field of transformer manufacturing technology, and in particular to a high-frequency transformer. Background Technology

[0002] In electronic devices, high-frequency transformers play a crucial role, converting alternating current into the required voltage and current. They also play an important role in many fields such as radio communication, medical equipment, and home appliances.

[0003] A high-frequency transformer is a power transformer that operates at a frequency exceeding that of an intermediate frequency. It is a crucial component of switching power supplies, and its working principle utilizes electromagnetic induction between adjacent windings to achieve power output transformation. The transformer mainly consists of a magnetic core and coils. The coils consist of two or more windings; the winding connected to the power supply is called the primary coil, and the remaining windings are called secondary coils. During operation, the primary coil generates an alternating magnetic field, which propagates through the magnetic core, enhancing the magnetic field strength. This enhanced magnetic field passes through the secondary coil, inducing an electromotive force (EMF). Since the secondary coil is connected to the output circuit, the induced EMF in the secondary coil completes signal transmission.

[0004] However, existing EE-type magnetic core high-frequency transformers have poor shielding effects and limited voltage resistance during use, which cannot meet the actual application requirements of output power of 1-6KW; therefore, there is an urgent need for a high-frequency transformer to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a high-frequency transformer to solve the technical problems of existing high-frequency transformers, such as poor shielding effect and inability to meet the application requirements of output power of 1-6KW.

[0006] The present invention discloses a high-frequency transformer comprising a base, magnetic cores, a frame, a coil, tape, and a temperature sensing wire. The frame has baffles at both ends, a winding groove in the middle, and an internal mounting groove. The magnetic cores are inserted into the mounting grooves of the frame in pairs. The coil is wound on the winding grooves of the frame. The tape has a double-layer structure, including an inner tape and an outer tape. The inner tape wraps around the outside of the two opposing magnetic cores, and the outer tape wraps around the outside of the inner tape. One end of the coil is connected to the temperature sensing wire, and the other end is connected to the base. The base is adhered to the magnetic core.

[0007] Preferably, the magnetic core has an E-type structure, with two magnetic cores forming a group, and the high-frequency transformer is provided with one or two groups of magnetic cores.

[0008] Preferably, an epoxy board is provided between the two magnetic cores on the same side, and the epoxy board and all the starting and ending leads of the coil must be fixed with adhesive.

[0009] Preferably, the tape is a high-temperature brown tape, the inner tape wraps around the magnetic core 3 times, and the outer tape wraps around the inner tape 1.5 times for fixation.

[0010] Preferably, a temperature sensor is connected to the end of the temperature sensing wire.

[0011] Preferably, the input and output lines of the coil are fitted with Teflon sleeves.

[0012] Preferably, the base includes a base plate and a plurality of integrally formed support columns disposed on the base plate. The base plate has a plurality of wire-passing slots on both sides for lead wires to pass through. The wire-passing slots are located on the outer side of the support columns. The bottom surface of the base plate is recessed inward to form a groove.

[0013] Preferably, the support column is vertically mounted on the base plate, and there are three, four, or five support columns. The base plate has bosses at the four corners of its bottom surface. The surface of the wire through hole is recessed inward to form a chamfer. The cross-section of the support column is circular, square, triangular, or polygonal. The base plate and the support column are made of bakelite thermosetting material.

[0014] Preferably, the high-frequency transformer includes four windings, namely winding N1, winding N2, winding N3 and winding N4. Winding N1 and winding N3 are connected and correspond to winding N2. Winding N4 is located on the same side as winding N1 and winding N3. The output end of winding N4 is connected to flying wire A and flying wire B. In addition, it also includes an X-ray.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0016] This high-frequency transformer mainly includes a base, magnetic core, frame, coil, tape, and temperature sensing wire. The base supports the transformer and secures the leads. The magnetic core is mounted on the frame to convert electromagnetic energy. The frame, positioned above the base, secures the coil and insulates it from the magnetic core. The frame is made of needle-free plastic and is wrapped with high-temperature tape before winding. The high-temperature tape is heat-resistant and provides insulation. One end of the temperature sensing wire is connected to the coil to sense its temperature, preventing operation under set high-temperature conditions and protecting the transformer. The other end of the wire is equipped with a temperature sensor with a sensing range of -40℃ to +125℃. Within this range, the transformer can operate normally; outside this range, the transformer will trip for protection.

[0017] The tape used in this high-frequency transformer includes an inner tape and an outer tape. The inner tape wraps around the outside of two opposing magnetic cores, bonding the two magnetic cores together as a whole. The outer tape wraps around the outside of the inner tape, bonding one or more sets of magnetic cores together as a whole. The inner and outer tapes serve as insulation and further provide sealing and shielding, ensuring good shielding performance of the high-frequency transformer.

[0018] The base of this high-frequency transformer mainly includes a base plate and a support column. The support column and the base plate are integrally formed, ensuring a more robust base plate structure, more stable support, and higher processing efficiency. Grooves are provided on the bottom surface of the base plate to facilitate the removal of the base plate and transformer structure during assembly. Multiple wire-passing slots are provided on the base plate, with the shape of the slots designed according to the shape of the leads, ensuring rapid installation and a tighter connection between the base plate and the coils and magnetic core. Bosses are provided at the four corners of the bottom surface of the base plate to facilitate solder penetration during wave soldering, improving the overall assembly efficiency of the transformer.

[0019] The high-frequency transformer of this invention mainly achieves the mutual conversion of electrical and magnetic energy through the cooperation of various components, and can meet the practical application of power conversion with an output power of 1-6KW. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0021] Figure 1 This is a three-dimensional structural schematic diagram of an embodiment of a high-frequency transformer according to the present invention;

[0022] Figure 2 This is a three-dimensional structural schematic diagram of another embodiment of a high-frequency transformer according to the present invention;

[0023] Figure 3 This is a schematic diagram of the split structure of an embodiment of a high-frequency transformer according to the present invention;

[0024] Figure 4 This is a three-dimensional structural schematic diagram of another embodiment of a high-frequency transformer according to the present invention;

[0025] Figure 5 This is a three-dimensional structural schematic diagram of another embodiment of a high-frequency transformer according to the present invention;

[0026] Figure 6 This is a three-dimensional structural schematic diagram of another embodiment of a high-frequency transformer according to the present invention;

[0027] Figure 7 This is an electrical schematic diagram of an embodiment of a high-frequency transformer according to the present invention;

[0028] Figure 8This is a schematic diagram of the winding structure of an embodiment of a high-frequency transformer according to the present invention;

[0029] Figure 9 This is a schematic diagram of the base structure of an embodiment of a high-frequency transformer according to the present invention.

[0030] In the diagram: 1. Base; 11. Base plate; 111. Boss; 12. Support column; 13. Wire guide hole; 131. Chamfer; 14. Groove; 2. Magnetic core; 3. Frame; 31. Baffle; 32. Winding groove; 33. Mounting groove; 4. Coil; 5. Adhesive tape; 51. Inner adhesive tape; 52. Outer adhesive tape; 6. Temperature sensing wire; 7. Temperature sensor; 8. Epoxy board. Detailed Implementation

[0031] This section will describe in detail specific embodiments of the present invention. Preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and overall technical solution of the present invention, but they should not be construed as limiting the scope of protection of the present invention.

[0032] like Figure 1-9 As shown, a high-frequency transformer of the present invention includes a base 1, a magnetic core 2, a frame 3, a coil 4, an adhesive tape 5, and a temperature sensing wire 6. The frame 3 has baffles 31 at both the front and rear ends, a winding groove 32 in the middle, and an installation groove 33 inside. The magnetic cores 2 are inserted into the installation grooves 33 of the frame 3 in pairs. The coil 4 is wound on the winding grooves 32 of the frame 3. The adhesive tape 5 has a double-layer structure, including an inner adhesive tape 51 and an outer adhesive tape 52. The inner adhesive tape 51 is wrapped around the outside of the two opposing magnetic cores 2, and the outer adhesive tape 52 is wrapped around the outside of the inner adhesive tape 51. One end of the coil 4 is connected to the temperature sensing wire 6, and the other end is connected to the base 1. The base 1 is bonded to the magnetic core 2.

[0033] This invention discloses a high-frequency transformer, mainly comprising a base 1, a magnetic core 2, a frame 3, a coil 4, adhesive tape 5, and a temperature sensing wire 6. The base 1 supports the transformer and fixes the leads. The magnetic core 2 is mounted on the frame 3, enabling electromagnetic energy conversion. The frame 3 is positioned above the base 1, fixing the coil 4 and insulating it from the magnetic core 2. The frame 3 is made of plastic needle-free material and is wrapped with high-temperature adhesive tape before winding. The adhesive tape 5 is also high-temperature resistant and provides insulation. One end of the temperature sensing wire 6 is connected to the coil 4 to sense its temperature, preventing the transformer from operating in high-temperature environments below a set threshold, thus protecting the transformer. The other end of the temperature sensing wire 6 is equipped with a temperature sensor with a sensing range of -40℃ to +125℃. Within this range, the transformer can operate normally; outside this range, the transformer will trip for protection. This high-frequency transformer, through the cooperation of its components, ultimately achieves the conversion between electrical and magnetic energy at the customer's installation location, meeting practical applications requiring power conversion from 1 to 6 kW.

[0034] In a preferred embodiment, refer to Figure 1-6 The high-frequency transformer has an E-type magnetic core 2, with two magnetic cores 2 forming a group. The high-frequency transformer may have one or two groups of magnetic cores. An epoxy board is placed between the two magnetic cores on the same side. The epoxy board 8 and all the starting and ending leads of the coil 4 must be fixed with adhesive. By setting the magnetic core 2 to an E-type structure, the middle of the magnetic core is inserted into the middle of the frame. During assembly, a layer of high-temperature tape is first wrapped around each group of magnetic cores to adjust the inductance. Then, the two magnetic cores are wrapped and fixed into a single structure with high-temperature tape. The epoxy board serves to insulate, isolate, and support, ensuring that the magnetic inductance of each group of magnetic cores is not affected. The epoxy board is 1mm thick.

[0035] In a preferred embodiment, refer to Figure 1-6 The high-frequency transformer uses high-temperature brown tape, with the inner tape wrapping the magnetic core three times and the outer tape wrapping the inner tape 1.5 times for fixation. A temperature sensor 7 is connected to the end of the temperature sensing wire 6; the NTC temperature sensor senses the temperature of the coil to protect the transformer. Teflon sleeves are fitted onto both the input and output wires of the coil 4, protecting the core wires.

[0036] In a preferred embodiment, refer to Figure 9The base 1 of the high-frequency transformer includes a base plate 11 and multiple integrally formed support columns 12 disposed on the base plate. Multiple wire-passing slots 13 are provided on both sides of the base plate 11 for lead wires to pass through. The wire-passing slots 13 are located on the outer side of the support columns 12. A groove 14 is formed by an inward indentation in the center of the bottom surface of the base plate 11. The support columns 12 are vertically mounted on the base plate 11. There are three, four, or five support columns 12. Bosses 111 are provided at the four corners of the bottom surface of the base plate 11. The surfaces of the wire-passing slots 13 are inwardly indented to form chamfers 131. The cross-section of the support columns 12 is circular, square, triangular, or polygonal. The base plate 11 and the support columns 12 are made of bakelite thermosetting material.

[0037] The transformer base 1 of this invention supports the coil 4 and the magnetic core 3, and also fixes the leads, thus supporting the product. It mainly includes a base plate 11 and a support column 12, wherein the support column 12 is integrally formed with the base plate 11. The base plate 1 and the support column 2 are made of bakelite thermosetting material, which has good insulation, heat resistance, and chemical corrosion resistance. By making the base plate 1 and the support column 2 integrally formed, the base plate structure is made more robust. By providing wire-passing slots 13 on both sides (inner or outer sides) of the base plate 11, and providing chamfers 131 on the wire-passing slots, it is ensured that the coil leads can pass through... The assembly efficiency is higher because the leads can be quickly inserted into the wire guide slots 13. The base plate 11 has grooves 14 on its bottom surface, which facilitates the removal of the base plate 11 and the transformer structure during assembly. The support pillars 12 are preferably provided in four parts. During installation, their tops rest on the magnetic core, and the leads at both ends of the magnetic core are inserted downwards into the wire guide slots 13. The shape of the wire guide slots 13 is set according to the shape of the leads, but they are mostly circular or square structures. The base plate 111 has bosses 111 on the four corners of its bottom surface, which facilitates the tin penetration of the transformer during wave soldering, thus improving the overall assembly efficiency of the transformer.

[0038] Reference Figure 1-3 The electrical performance values ​​of the high-frequency transformer of the present invention, tested in an environment of 25°C, are as follows: inductance, L(1-2) = 580uH-720uH in a test environment of 1KHz / 1V; leakage inductance, LK(1-2) = 3.5uHMax in a test environment of 10KHz / 1V; inter-turn test, N1 to N3 = 0.6KV in a test environment of 3 pulses; DC resistance, DC(1-2) = 9.0mΩMAX in a test environment of 1KHz / 0.1V, temperature sensing wire = 18KΩMAX, 3-4 = 0.50mΩMAX.

[0039] Reference Figure 7 and 8The high-frequency transformer of the present invention includes four windings, namely winding N1, winding N2, winding N3 and winding N4. Winding N1 and winding N3 are connected by an epoxy board and correspond to winding N2. Winding N4 is located on the same side as winding N1 and winding N3. The output end of winding N4 is connected to flying wire A and flying wire B, which are the temperature sensing wires of the temperature sensor. It also includes an X-ray. The X-ray is a reserved wire that is not cut. It is led out from the top of the PIN1-3 side with a sleeve. After winding N2, it is folded back to the wire slot to continue winding N3. Two baffle tapes are added to both ends of winding N1 and winding N3. Each end of the copper foil of winding N2 is soldered with a 1.5*2P lead wire, for a total of four copper foils. Double-layer high-temperature tape is used for backing, and the two sides are folded back to the minimum of 8.

[0040] The winding structure table of the winding of the present invention is shown below. Figure 1 :

[0041]

[0042]

[0043] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A high-frequency transformer, characterized in that: The device includes a base, magnetic cores, a frame, a coil, tape, and a temperature sensing wire. The frame has baffles at both ends and a winding groove in the middle, with an internal mounting groove. The magnetic cores are inserted into the mounting grooves of the frame in pairs. The coil is wound around the winding grooves of the frame. The tape has a double-layer structure, including an inner tape and an outer tape. The inner tape wraps around the outside of the two opposing magnetic cores, and the outer tape wraps around the outside of the inner tape. One end of the coil is connected to the temperature sensing wire, and the other end is connected to the base. The base is adhered to the magnetic core.

2. The high-frequency transformer as described in claim 1, characterized in that, The magnetic core has an E-type structure, with two magnetic cores forming a group. The high-frequency transformer is equipped with one or two groups of magnetic cores.

3. The high-frequency transformer as described in claim 1, characterized in that, An epoxy board is provided between the two magnetic cores on the same side, and the epoxy board and all the starting and ending leads of the coil must be fixed with glue.

4. The high-frequency transformer as described in claim 1, characterized in that, The tape is a high-temperature brown tape. The inner tape wraps around the magnetic core 3 times, and the outer tape wraps around the inner tape 1.5 times for fixation.

5. The high-frequency transformer as described in claim 1, characterized in that, A temperature sensor is connected to the end of the temperature sensing wire.

6. The high-frequency transformer as described in claim 1, characterized in that, The coil's input and output lines are all fitted with Teflon sleeves.

7. The high-frequency transformer as described in claim 1, characterized in that, The base includes a base plate and a plurality of integrally formed support columns disposed on the base plate. The base plate has a plurality of wire-passing slots on both sides for lead wires to pass through. The wire-passing slots are located on the outside of the support columns. The bottom surface of the base plate is recessed inward to form a groove.

8. The high-frequency transformer as described in claim 7, characterized in that, The support column is vertically mounted on the base plate. There are three, four, or five support columns. The base plate has protrusions at the four corners of its bottom surface. The surface of the wire through slot is recessed inward to form a chamfer. The cross-section of the support column is circular, square, triangular, or polygonal. The base plate and support columns are made of bakelite thermosetting material.

9. The high-frequency transformer as described in claim 7, characterized in that, The high-frequency transformer includes four windings: winding N1, winding N2, winding N3, and winding N4. Windings N1 and N3 are connected and correspond to winding N2. Winding N4 is located on the same side as windings N1 and N3. The output terminal of winding N4 is connected to flying wire A and flying wire B. It also includes an X-ray.

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