Transformer based on PCB structure

Abstract

The invention relates to the field of transformers, and provides a transformer based on a PCB structure, which comprises a PCB, a soft magnetic material, a winding coil and an iron core material, the PCB is provided with a plurality of layers, and two groups of embedding ports are formed in the PCB; the soft magnetic material serving as a magnetic core is embedded into the embedding port of each layer of PCB; a plurality of circles of winding coils are printed on the surface of each layer of PCB, and the winding coils are spirally wound by taking the soft magnetic material as an axis; each layer of PCB is provided with a via hole, the via holes are located at the winding coil, and the via holes of each layer of PCB correspond to each other and are communicated one by one; the number of the iron core materials is two, one group of the iron core materials covers the PCB on the uppermost layer, and the other group of the iron core materials is located on the bottom face of the PCB on the lowermost layer, so that a closed magnetic circuit is formed. The invention has the effect of breaking through the traditional high-voltage limitation.

Description

Technical Field

[0001] This application relates to the field of transformers, and in particular to a transformer based on a PCB structure. Background Technology

[0002] A transformer is a device that uses the principle of electromagnetic induction to change alternating current voltage. Its main components are the primary coil, the secondary coil, and the iron core (magnetic core).

[0003] Traditional transformers mainly use ferrite or iron-based materials as magnetic cores and achieve voltage transformation through coil windings. However, traditional transformers are large and heavy, making it difficult to meet the miniaturization requirements of modern electronic equipment. Alternatively, planar transformers can be used, which reduce the size through flat coils and thin magnetic cores, but are still limited by the magnetic core material and insulation performance. Summary of the Invention

[0004] To address the aforementioned issues, this application provides a transformer based on a PCB structure.

[0005] This application provides a PCB-based transformer with the following technical solution: A transformer based on a PCB structure includes a PCB board, a soft magnetic material, winding coils, and a core material. The PCB board has several layers and two sets of insertion slots. The soft magnetic material, serving as a magnetic core, is embedded in the insertion slots of each layer of the PCB board. Several turns of the winding coil are printed on the surface of each layer of the PCB board, and the winding coils are spirally wound around the soft magnetic material as the axis. Each layer of the PCB board has through holes located at the winding coils, and the through holes of each layer of the PCB board correspond to each other and are interconnected. The core material consists of two sets, one set covering the uppermost layer of the PCB board and the other set located on the bottom surface of the lowermost layer of the PCB board, forming a closed magnetic circuit.

[0006] By adopting the above technical solution and using a PCB board structure, the size of the transformer is significantly reduced. By using multi-layer PCB boards, the number of integrated printed winding coils on the PCB boards can be increased. The integrated printed winding coils are implemented by PCB circuitry, resulting in better voltage consistency and higher production efficiency. At the same time, the more layers of the PCB board, the more winding coils there are. Combined with soft magnetic materials, the transformation capacity of the high-voltage transformer can be adjusted, thus breaking through the traditional high-voltage limitations. The entire electromagnetic wire is connected by the through holes of each PCB board. After selecting and stacking suitable PCB boards, the magnetic circuit is closed by two sets of iron core materials, forming a complete transformer.

[0007] Optionally, an insulating film is provided between adjacent PCB boards and between the PCB board and the iron core material.

[0008] By adopting the above technical solution, the insulating film separates adjacent PCB boards to ensure electrical insulation between windings, prevent high voltage breakdown, and also provide a certain pressure resistance. This avoids excessive pressure on the bottom PCB board due to the continuous stacking of PCB boards, which could cause damage. The insulating film makes the pressure resistance of each PCB board better.

[0009] Optionally, a plurality of through holes are provided around the winding coil, and the insulating film between adjacent PCB boards does not block the through holes, while the insulating film between the PCB board and the core material covers the through holes.

[0010] By adopting the above technical solution, setting multiple sets of through holes can increase the magnetic flux of the magnetic field lines, while the insulating film does not block the through holes to ensure the stable connection of the magnetic field lines. At the same time, the insulating film is located around the through holes to cover them, so as to avoid high voltage breakdown.

[0011] Optionally, the soft magnetic material is selected from ferrite materials.

[0012] By adopting the above technical solution, ferrite has the characteristics of high magnetic permeability and low loss. When applied to PCB boards, it can realize the functions of energy conversion and magnetic field control through its own magnetism.

[0013] Optionally, the thickness of the soft magnetic material is the same as the thickness of the PCB board.

[0014] By adopting the above technical solution, when the soft magnetic material is embedded in the PCB board, it can provide magnetic conversion without affecting other PCB boards. At the same time, if the PCB board or the soft magnetic material is damaged, the soft magnetic material can be removed or replaced after removing the single-layer PCB board without affecting the application of other PCB boards.

[0015] Optionally, the wall of the embedding port is provided with a card interface, and the soft magnetic material is provided with a snap-fit ​​protrusion. The snap-fit ​​protrusion is inserted into the embedding port from the card interface. By rotating, the snap-fit ​​protrusion is offset from the entrance of the card interface, thereby realizing the snap-fit ​​of the soft magnetic material.

[0016] By adopting the above technical solution, the snap-fit ​​method can facilitate the detachable connection between the soft magnetic material and the embedding port, making it easy to replace or repair the soft magnetic material, while also saving consumables.

[0017] Optionally, the soft magnetic material has a feeding groove on its top surface.

[0018] By adopting the above technical solution, the material trough can be used to easily remove or replace soft magnetic materials from the insertion port.

[0019] Optionally, the card interface is an L-shaped or N-shaped arc-shaped opening.

[0020] By adopting the above technical solution, the arc-shaped L-shaped or N-shaped opening allows soft magnetic materials to be more stably and easily snapped or disassembled through the snap-fit ​​protrusion.

[0021] Optionally, the PCB board is connected to power terminals, which are divided into two groups, each group consisting of a positive terminal and a negative terminal.

[0022] By adopting the above technical solution, external current is connected to the winding coil or output winding coil through the power connection terminal to provide voltage transformation or current conversion.

[0023] Optionally, a single PCB board is divided into two sides along the vertical direction: side A and side B. Both sides A and B are provided with the winding coils. The PCB board is provided with conductive holes. The conductive holes in each layer of the PCB board are the conduction paths for the winding coils in each layer to be connected in series or in parallel. Conductive material is provided in the conductive holes of each layer of the PCB board. The winding coils between all layers of the PCB board and between sides A and B are connected in series or in parallel through the conductive material.

[0024] By adopting the above technical solution, the number of winding coils on a single-layer PCB board can be increased through a multi-layer plate structure. The more coils there are, the greater the induced potential difference becomes. At the same time, the number of PCB boards can be reduced to further compress the volume.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. The PCB board structure significantly reduces the size of the transformer. By using multiple PCB boards, the number of integrated printed winding coils on the PCB board can be increased. The integrated printed winding coils are implemented by PCB circuitry, resulting in better voltage consistency and higher production efficiency. At the same time, the more PCB boards there are, the more winding coils there are. Combined with soft magnetic materials, the transformation capacity of the high-voltage transformer can be adjusted, thus breaking through the traditional high-voltage limitations. The entire electromagnetic wire is connected by the through holes of each PCB board. After selecting and stacking suitable PCB boards, the magnetic circuit is closed by two sets of iron core materials to form a complete transformer. 2. The insulating film separates adjacent PCB boards to ensure electrical insulation between windings, prevent high voltage breakdown, and also provide a certain degree of pressure resistance. This prevents the bottom PCB board from being damaged due to excessive pressure caused by the continuous stacking of PCB boards. The insulating film makes the pressure resistance of each PCB board better. 3. Setting multiple sets of through holes can increase the magnetic flux of the magnetic field lines, while the insulating film does not block the through holes to ensure the stable connection of the magnetic field lines. At the same time, the insulating film is located around the through holes to cover them to avoid high voltage breakdown. 4. Ferrites have the characteristics of high magnetic permeability and low loss. When applied to PCB boards, they can achieve energy conversion and magnetic field control through their own magnetism. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the first cross-sectional structure of the transformer in some embodiments of this application; Figure 2 This is a first top view of the PCB board in some embodiments of this application; Figure 3 This is a second top view of the PCB board in some embodiments of this application; Figure 4 This is a three-dimensional structural schematic diagram of the soft magnetic material and the embedding port in some embodiments of this application; Figure 5 This is a first exploded view of the PCB board in some embodiments of this application; Figure 6 This is a schematic diagram of parallel wiring of PCB conductive materials in some embodiments of this application; Figure 7 This is a second exploded view of the PCB board in some embodiments of this application; Figure 8 This is a schematic diagram of the series routing of PCB conductive materials in some embodiments of this application; Figure 9 This is a schematic diagram of a second cross-sectional structure of the transformer in some embodiments of this application; Figure 10 This is a third top view of the PCB board in some embodiments of this application; Figure 11 This is a schematic diagram of the exploded structure of the limiting rod and the vortex arc surface protrusion in some embodiments of this application; The markings in the attached diagram are as follows: 1. PCB board, 10. Conductive hole, 11. Embedding port, 12. Through hole, 13. Snap-in interface, 14. Vortex-shaped notch, 15. Vortex-shaped arc protrusion, 16. Limiting hole, 2. Soft magnetic material, 21. Material picking slot, 22. Snap-in protrusion, 3. Winding coil, 31. Conductive material, 32. Electrical terminal, 4. Iron core material, 5. Insulating film, 6. Limiting rod, 7. Nut, 8. Disassembly rod. Detailed Implementation

[0027] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand the advantages and effects of this application from the information disclosed herein. This application can also be implemented or applied through other different specific embodiments. Various details in this application can also be modified or changed according to different viewpoints and application systems without departing from the spirit of this application. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0028] The embodiments of this application will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can easily implement the application. This application may be embodied in many different forms and is not limited to the embodiments described herein.

[0029] In this application, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics represented in connection with that embodiment or example, which are included in at least one embodiment or example of this application. Furthermore, the specific features, structures, materials, or characteristics represented may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate different embodiments or examples represented in this application, as well as features of different embodiments or examples.

[0030] Furthermore, the terms "first" and "second" are used only to indicate an objective and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the representation of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0031] Throughout this specification, when it is said that a device is "connected" to another device, this includes not only "direct connection" but also "indirect connection" by placing other components in between. Furthermore, when it is said that a device "comprises" a certain constituent element, unless otherwise stated otherwise, this does not exclude other constituent elements, but rather implies that other constituent elements may be included.

[0032] The following is in conjunction with the appendix Figure 1 - Appendix Figure 11 This application will be described in further detail below.

[0033] This application discloses a transformer based on a PCB structure.

[0034] A transformer based on PCB structure, reference Figure 1As shown, it includes a PCB board 1, a soft magnetic material 2, a winding coil 3, and an iron core material 4. The PCB board 1 has several layers, and two sets of insertion slots 11 are opened on the PCB board 1. Each layer of PCB board 1 can increase the number of coils and the high voltage resistance required by the high voltage transformer. A certain number of PCB boards 1 are stacked according to the requirements of the high voltage transformer.

[0035] Each PCB board 1 has a soft magnetic material 2 embedded in its inlet 11 as a magnetic core. When the soft magnetic material 2 is used as a magnetic core, it provides the magnetic circuit part for induction, forming a magnetic path with magnetic field lines. The inlet 11 can be a rectangular or circular opening, and the corresponding soft magnetic material 2 is a rectangular columnar structure or a cylindrical structure.

[0036] Each PCB board 1 has several turns of winding coil 3 printed on its surface. The winding coil 3 is spirally wound around the soft magnetic material 2, forming several turns of winding coil 3. The two sets of soft magnetic materials 2, together with the two sets of winding coil 3, provide induced electromotive forces with different height differences to achieve voltage regulation. The spiral winding can increase or decrease the induced electromotive force generated according to the number of turns.

[0037] The winding coil 3 is printed on the surface of the PCB board 1. The PCB board 1 has the functions of good conductive lines and insulating base plate, and has the effect of high temperature resistance, so that the winding coil 3 can obtain a stable connection. At the same time, the winding coil 3 can be printed uniformly on each layer of the PCB board 1 to improve the speed of production.

[0038] Each PCB board 1 has a through hole 12 located at the winding coil 3. The through holes 12 of each PCB board 1 correspond to each other and are connected one by one. After the multiple PCB boards 1 are stacked together, multiple sets of winding coils 3 are formed to form an integral electromagnetic winding. The through holes 12 connect the electromagnetic lines of the multiple sets of winding coils 3 to each other.

[0039] The core material 4 is provided in two sets. One set covers the top surface of the uppermost PCB board 1, and the other set is placed at the bottom of the lowermost PCB board 1 to form a closed magnetic circuit. The core material 4 is used to form a loop in the overall electromagnetic circuit. The core material 4 is installed on the uppermost and lowermost PCB boards 1 respectively to close the overall magnetic circuit and form a complete transformer.

[0040] Among them, the iron core material 4 can be a rectangular plate material, slightly larger than the PCB board 1, so that the iron core material 4 can cover the PCB board 1.

[0041] Specifically, the use of PCB board 1 significantly reduces the size of the transformer. By using multiple layers of PCB board 1, the number of integrated printed winding coils 3 on PCB board 1 can be increased. The integrated printed winding coils 3 are implemented by PCB circuitry, resulting in better voltage consistency and higher production efficiency. At the same time, the more layers of PCB board 1 there are, the more winding coils 3 there are. Combined with soft magnetic material 2, the transformation capacity of the high-voltage transformer can be adjusted, thus breaking through the traditional high-voltage limitations. The entire electromagnetic wire is connected by the through holes 12 of each layer of PCB board 1. After selecting and stacking suitable PCB boards 1, the magnetic circuit is closed by two sets of iron core materials 4, forming a complete transformer. At the same time, when any PCB board 1 is damaged, only the damaged PCB board 1 needs to be replaced, without replacing the entire transformer, saving consumables and facilitating maintenance.

[0042] Furthermore, an insulating film 5 is provided between adjacent PCB boards 1, and an insulating film 5 is also provided between PCB board 1 and iron core material 4. The insulating film 5 can be made of polyimide film or other high-performance insulating materials. The insulating film 5 separates adjacent PCB boards 1 to ensure electrical insulation between windings, prevent high voltage breakdown, and also provide a certain pressure resistance effect to avoid the bottom PCB board 1 being subjected to excessive pressure and damaged due to the continuous stacking of PCB boards 1. The insulating film 5 makes the pressure resistance effect of each layer of PCB board 1 better. Furthermore, several through holes 12 are provided around the winding coil 3, and the insulating film 5 does not block the through holes 12. The through holes 12 are used to connect the electromagnetic lines of the winding coil 3 on the overall PCB board 1. Therefore, setting multiple sets of through holes 12 can increase the magnetic flux of the magnetic field lines. The insulating film 5 does not block the through holes 12 to ensure the stable connection of the magnetic field lines. At the same time, the insulating film 5 is located around the through holes 12 and covers them. However, the insulating film 5 set between the iron core material 4 and the PCB board 1 needs to cover the through holes 12 to avoid high voltage breakdown. Each layer of the PCB board 1 is provided with an insulating film 5, thereby improving the anti-breakdown effect.

[0043] Furthermore, the soft magnetic material 2 is made of ferrite or similar high-permeability material. Ferrite has the characteristics of high permeability and low loss. When applied to PCB board 1, it can realize the functions of energy conversion and magnetic field control through its own magnetism.

[0044] The thickness of the soft magnetic material 2 is the same as that of the PCB board 1, so that when the soft magnetic material 2 is embedded in the PCB board 1, it can provide magnetic conversion without affecting other PCB boards 1. At the same time, if the PCB board 1 or the soft magnetic material 2 is damaged, the soft magnetic material 2 can be removed or replaced after the single-layer PCB board 1 is removed, without affecting the application of other PCB boards 1.

[0045] In some embodiments, reference Figure 3As shown, the connection between the soft magnetic material 2 and the PCB board 1 is a detachable connection. Specifically, a card interface 13 is provided at the wall of the insertion port 11. The card interface 13 can be circular, and the corresponding soft magnetic material 2 can be circular cylindrical. The soft magnetic material 2 is provided with a snap-fit ​​protrusion 22, which is located at one-third of the vertical direction of the soft magnetic material 2 from top to bottom. This allows the soft magnetic material 2 to be inserted into the insertion port 11 first, and then the snap-fit ​​protrusion 22 enters the insertion port 11 from the card interface 13. Then, by rotating, the snap-fit ​​protrusion 22 is offset from the entrance of the card interface 13, so that the soft magnetic material 2 is restricted by the snap-fit ​​protrusion 22 and cannot be removed from the insertion port 11, thereby realizing the snap-fit ​​of the soft magnetic material 2.

[0046] This method allows for convenient detachable connection between the soft magnetic material 2 and the insertion port 11, facilitating the replacement or repair of the soft magnetic material 2 and saving consumables. For example, if any PCB board 1 is damaged by high voltage, causing the winding coil 3 to be damaged, the soft magnetic material 2 can be rotated in the opposite direction to make the snap-fit ​​protrusion 22 align with the snap-fit ​​interface 13. Then, the soft magnetic material 2 can be removed from the insertion port 11, and a new PCB board 1 can be replaced to install the soft magnetic material 2, thereby realizing the reuse of the soft magnetic material 2.

[0047] Furthermore, the top surface of the soft magnetic material 2 is provided with a material picking groove 21. The material picking groove 21 can be two sets of opposing arc-shaped grooves. After the power is turned off, a tool or a finger can be inserted and a relative clamping force is applied to rotate the soft magnetic material 2 so that the snap-fit ​​protrusion 22 aligns with the snap-fit ​​interface 13 and is pulled away from the insertion port 11 to remove the soft magnetic material 2. The same applies when inserting it.

[0048] Furthermore, refer to Figure 4 As shown, when the card interface 13 is an L-shaped opening with an arc surface, the locking protrusion 22 moves down along the vertical direction of the L-shape. After moving to the corner, it rotates in the horizontal direction, so that the locking protrusion 22 cannot be pulled up and down in the vertical direction, thus realizing the locking function. The arc surface is to fit the opening wall of the card interface 13, so as to facilitate the rotation of the soft magnetic material 2.

[0049] Alternatively, when using an N-type opening with a curved surface, the snap-fit ​​protrusion 22 first enters the bottom along the vertical opening, and then the soft magnetic material 2 is rotated until the snap-fit ​​protrusion 22 rotates to the horizontal end of the snap-fit ​​interface 13, and then snaps in vertically. Compared with the L-type opening, this snap-fit ​​method has an extra layer of snap-fit ​​effect, making it impossible for the soft magnetic material 2 to rotate at the end. It needs to be pulled vertically first, then rotated to the exit direction of the snap-fit ​​interface 13 and aligned with it. Finally, the snap-fit ​​protrusion 22 is pulled out from the snap-fit ​​interface 13 vertically to complete the separation. Compared with the L-type opening, the snap-fit ​​effect is more stable. The illustration uses the N-type opening as an example.

[0050] In some embodiments, the PCB board 1 is connected to power terminals 32. Because voltage transformation is required, two sets of winding coils 3 with different numbers of turns are provided on a single PCB board 1. Therefore, the power terminals 32 are divided into two groups, each with a positive terminal and a negative terminal, corresponding to the positive and negative electrodes. External current is connected to the winding coil 3 or the output winding coil 3 through the power terminals 32 to provide voltage transformation or current conversion. The style of the power terminals 32 is determined according to the requirements. When the circuit is in series, the power terminals 32 can be set on each layer. When the circuit is in parallel, the power terminals 32 can be set on the top PCB board 1 and the bottom PCB board 1.

[0051] Furthermore, a single PCB board 1 has several layers along the vertical direction, with the outermost layer having two sides divided into side A and side B, i.e. side A is the top surface and side B is the bottom surface, or side A is the bottom surface and side B is the top surface. The single board has a multi-layer structure, and both side A and side B have winding coils 3, which increases the number of winding coils 3 on the single PCB board 1 and adjusts the transformer capacity of the high voltage transformer.

[0052] All conductive holes 10 in each layer of PCB board 1 serve as the conduction paths for the winding coils 3 in each layer, either in series or in parallel. That is, all layers of a single PCB board 1 and all PCB boards 1 have conductive holes 10 on a unified axis to provide series or parallel conduction paths for the winding coils 3 to connect in the circuit. Conductive material 31 is provided inside the conductive holes 10, such as metal wire cores or solder structures for energizing. The conductive material 31 enables the winding coils 3 in each layer of PCB board 1 and between the A and B sides to be connected in series or in parallel. The conductive material 31 is connected to the power terminals 32 of the top and bottom layers to achieve circuit connection.

[0053] Furthermore, depending on whether the winding coil 3 is connected in series or in parallel, there are two different connection methods.

[0054] refer to Figure 5 and Figure 6 As shown, when the winding coils 3 are connected in parallel, the printing of the winding coils 3 is based on side A of the PCB board 1, and the pattern of the winding coils 3 is transferred and printed on side B, that is, the pattern of the winding coils 3 on side A and side B of the PCB board 1 is the same.

[0055] Wiring grooves are formed on the surfaces of the top and bottom PCB boards 1. Conductive material 31 is connected in the wiring grooves and connected to the terminals 32. The conductive material 31 is connected to the positive terminal outside the winding coil 3 along the wiring grooves, providing a positive circuit path. The conductive hole 10 is located at the initial end of the inner ring of the winding coil 3. Since the initial end positions of the inner rings on surfaces A and B are the same, conductive material 31 is also inserted in the conductive hole 10. The conductive material 31 can be used to connect the initial ends of all winding coils 3 to the negative terminal, and the terminals 32 are connected to the bottom PCB board 1 to form a negative terminal path, thereby realizing a positive and negative terminal path. In this way, the top surface of the top PCB board 1 does not have the winding coil 3 printed on it, and the bottom PCB board 1 does not have the winding coil 3 printed on it. Therefore, when the wiring grooves are formed, there will be no interference with the winding coil 3.

[0056] On the other hand, reference Figure 7 and Figure 8 As shown, when the winding coils 3 are connected in series, the printing of the winding coils 3 is based on the PCB board 1, and the pattern of the winding coils 3 on side A is mirrored and printed on side B, that is, the outer ends of the winding coils 3 on side A and side B of the PCB board 1 are staggered.

[0057] Each PCB board 1 has a wiring groove on its surface, and a conductive material 31 is connected in the wiring groove. The series connection method is different from the parallel connection method. In the series connection method, the top PCB board 1 is connected to the positive terminal and the bottom PCB board 1 is connected to the negative terminal. At the same time, the conductive material 31 is connected to the positive terminal of the A side of the top PCB board. The conductive holes 10 are located at the inner initial end and the outer end of the winding coil 3, and at least two conductive holes 10 are provided at the outer end to improve the compatibility during connection. The conductive material 31 connects the inner initial end of the winding coil 3 on the A side to the inner initial end of the winding coil 3 on the B side through the conductive holes 10, so that the current can enter from the outer end of the winding coil 3 on the A side and pass through the winding coil 3 on the A side to the winding coil 3 on the B side. When it reaches the outer end of the winding coil 3 on the B side, it is connected to the external power terminal 32 through the wiring groove. The power terminal 32 is connected in series with all PCB boards 1.

[0058] Upon reaching the second PCB board 1, the A and B sides of the second PCB board 1 are interchanged, so that the B side of the first PCB board 1 is positioned opposite the B side of the second PCB board 1. The conductive material 31 directly transmits current from the B side of the first PCB board 1 to the B side of the second PCB board 1 through the terminal 32, thereby achieving circuit connection. Subsequently, each PCB board 1 is flipped, i.e., A side faces A side and B side faces B side. Because the positions of the outer ends of the winding coils 3 on the A side and B side are different, but the opposite sides of the PCB board 1 of adjacent layers are the same, it is ensured that the conductive material 31 directly connects all the winding coils 3. When reaching the last layer, it is connected to the negative terminal 32 to achieve circuit conduction.

[0059] Compared to parallel connection, the conductive material 31 in parallel connection needs to pass through all the conductive holes 10 of PCB board 1, thus requiring it to penetrate the insulating layer. In contrast, the series connection does not require penetrating the insulating layer and can bypass the insulating layer by passing through the power terminal 32 outside the PCB board 1. Although both series and parallel connections can achieve circuit connection, the series connection is preferred.

[0060] In some embodiments, reference Figure 9 As shown, each PCB board 1 has a vortex-shaped notch 14 on its top surface, and the vortex-shaped notches are distributed at the corners of each PCB board 1. That is, when the PCB board 1 is a rectangular board, vortex-shaped notches 14 are opened at the four corners of the PCB board 1. Each PCB board 1 has a vortex-shaped arc protrusion 15 on its bottom surface.

[0061] When adjacent PCB boards 1 are stacked together, the upper PCB board 1 inserts into the vortex-shaped recesses 14 of the lower PCB board 1 through the vortex-shaped protrusions 15 at each corner of the bottom surface. The arc-shaped wall of the vortex-shaped recesses 14 makes it easier for the vortex-shaped protrusions 15 to fill the bottom of the vortex-shaped recesses 14. After each vortex-shaped protrusion 15 is inserted into the corresponding vortex-shaped recesses 14, the upper PCB board 1 and the lower PCB board 1 are stably stacked.

[0062] By interlocking the spiral arc-shaped protrusions 15 and the spiral recesses 14, rapid positioning and rapid stacking can be achieved, allowing adjacent PCB boards 1 to be stacked quickly with their edges and corners flush. At the same time, the spiral arc-shaped protrusions and spiral recesses 14 at each corner are used for limiting the PCB boards 1 to prevent them from being misaligned, thus improving the stability of the PCB board 1 connection.

[0063] The vortex-shaped notches 14 and corresponding vortex-shaped protrusions 15 are designed to provide pressure resistance. The vortex-shaped protrusions 15 are made of soft insulating material and are thicker than the depth of the vortex-shaped notches 14. The extra thickness is equal to the thickness of the insulating film 5, which allows the vortex-shaped protrusions 15 at the corners to provide pressure resistance. The contact between the vortex-shaped notches 14 and the corresponding vortex-shaped protrusions 15 increases the bearing area. The load-bearing capacity provided by the four corners increases the force balance. Combined with the insulating film 5 covering the surface of the PCB board 1, the pressure on each layer of the PCB board 1 is distributed to the vortex-shaped protrusions 15 and the insulating film 5, thereby improving the stability of the connection and the pressure resistance.

[0064] If an insulating layer is provided, a penetration opening matching the maximum diameter of the vortex-shaped notch 14 can be made on the insulating layer for the vortex-shaped arc protrusion 15 to pass through. The vortex-shaped arc protrusion 15 is made of soft insulating material and can replace the insulating layer at the penetration opening to provide insulation and protection against breakdown.

[0065] Further reference Figure 9 and Figure 10 As shown, an installation groove can be opened on the iron core material 4. The installation groove is hexagonal and a nut 7 is placed in the installation groove. The nut 7 matches the size of the installation groove. The vortex arc-shaped protrusion 15, the PCB board 1 and the iron core material 4 are all provided with interconnected limiting holes 16. A limiting rod 6 is inserted into the limiting hole 16, and both ends of the limiting rod 6 are provided with external threads. The end of the limiting rod 6 with external threads is located in the installation groove and is screwed to the nut 7.

[0066] The bottom iron core material 4 can have its mounting groove facing the ground, and the top iron core material 4 can also have its mounting groove facing the ground, so that the top nut 7 will not be embedded in the mounting groove, making it easy to unscrew the nut 7 for subsequent disassembly. Depending on the requirements, the mounting groove can also be omitted. The mounting groove can serve an aesthetic purpose, while without the mounting groove, the nut 7 does not need to be embedded and is exposed outside the iron core material 4.

[0067] Both the limit rod 6 and the nut 7 can be made of insulating materials, such as high-temperature resistant plastic.

[0068] The limiting rod 6 connects all PCB boards 1, vortex arc-shaped protrusions 15 and two sets of iron core materials 4 into one unit, and the limiting rod 6 is fixed by the nut 7. When the iron core material 4 is a rectangular plate, there are four sets of limiting rods 6, which are located at the four corners of the rectangular plate and correspond to the vortex arc-shaped protrusions 15.

[0069] Further, refer to Figure 9 and Figure 11 As shown, the limiting rod 6 is engraved with scale lines, and the spacing of the scale lines is consistent with the thickness of the PCB board 1; the two ends of the limiting rod 6 are also screwed with disassembly rods 8, which are either straight rods or cross rods, with a threaded hole in the middle, and are screwed to the external threads at both ends of the limiting rod 6 through the threaded hole; the limiting hole 16 is shaped according to the shape of the disassembly rod 8. For example, if the disassembly rod 8 is a straight rod, then the limiting hole 16 is a straight hole.

[0070] When the transformer is operating normally, the limit rod 6 is locked onto the core material 4 by the nut 7, so that the core material 4 is covered and fixed to the PCB board 1 by the limit rod 6.

[0071] When a transformer is damaged, such as due to prolonged use or excessive dust and humidity causing current breakdown, a certain PCB board 1 may be damaged and needs to be replaced. However, since PCB boards 1 are stacked on top of each other, they need to be removed one by one, which will affect the speed of replacement or maintenance. Therefore, the limit rod 6 and the disassembly rod 8 are used.

[0072] Depending on the requirements, if an installation slot is provided, the top nut 7 needs to be removed first. During this process, the entire transformer can be raised before proceeding. Then, push the limit rod 6 downwards to push the limit rod 6 out of the installation slot of the bottom core material 4. Then, unscrew the bottom nut 7 and replace it with the disassembly rod 8. If no installation slot is provided, directly unscrew the nut 7 at the bottom core material 4 and replace the disassembly rod 8, while screwing the limit rod 6 at the top core material 4 into the nut 7.

[0073] After the disassembly rod 8 is installed on the limiting rod 6, the limiting rod 6 is rotated to align the disassembly rod 8 with the limiting hole 16, allowing the disassembly rod 8 to pass through the limiting hole 16. Then, the top iron core material 4 is lifted using lifting equipment. After the iron core material 4 is lifted, it separates from the top PCB board 1. The limiting rod 6 will also gradually extend from the top PCB board 1. According to the position of the damaged PCB board 1, observe the scale on the limiting rod 6. When the scale reaches the PCB board 1 above the damaged PCB board 1, rotate the limiting rod 6 to make the disassembly rod 8 misaligned with the limiting hole 16. The disassembly rod 8 cannot pass through the limiting hole 16. At this time, the iron core material 4 will drive the PCB board 1 above the damaged PCB board 1 to rise synchronously. The damaged PCB board 1 is exposed on the top layer, and the worker can then remove the damaged PCB board 1 and replace it with a new PCB board 1.

[0074] After replacement, lower the core material 4 and PCB board 1, stacking the upper PCB board 1 with the new PCB board 1. Then rotate the limiting rod 6 to align the disassembly rod 8 with the limiting hole 16. Gradually lower the core material 4, and the limiting rod 6 and disassembly rod 8 will extend out of the bottom core material 4. The disassembly rod 8 can then be unscrewed and replaced with nut 7 to complete the replacement of the damaged PCB board 1. This method can improve the efficiency of replacing the damaged PCB board 1.

[0075] In the case where the conductive material 31 is introduced to connect the circuit, and each layer needs to be replaced for maintenance, when connected in parallel, the conductive material 31 is connected to the winding coil 3 of each layer by contact connection, that is, the inner and outer ends of the winding coil 3 are in contact with the conductive material 31. This ensures that the circuit is conductive and does not affect the replacement of each PCB board 1. When connected in series, the conductive material 31 in the conductive hole 10 of the inner ring of the winding coil 3 is not connected to the conductive hole 10 of the adjacent layer. It is only necessary to replace the external power terminal 32 of the adjacent PCB board 1 with contact connection. When removing the PCB board 1, the A-side of the PCB board 1 is staggered with the B-side of the PCB board 1. Therefore, the two PCB boards 1 need to be removed simultaneously to ensure that the opposite surfaces of the adjacent PCB boards 1 are of the same type.

[0076] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A transformer based on a PCB structure, characterized in that, The system includes a PCB board (1), a soft magnetic material (2), a winding coil (3), and an iron core material (4). The PCB board (1) has several layers and two sets of insertion slots (11) are provided on the PCB board (1). The soft magnetic material (2) serving as a magnetic core is embedded in the insertion slot (11) of each layer of the PCB board (1). Several turns of the winding coil (3) are printed on the surface of each layer of the PCB board (1). The winding coil (3) is spirally wound with the soft magnetic material (2) as the axis. Each layer of the PCB board (1) has a through hole (12). The through hole (12) is located at the winding coil (3), and the through holes (12) of each layer of the PCB board (1) correspond to each other and are connected one by one. The iron core material (4) has two sets, one set covering the uppermost layer of the PCB board (1) and the other set located on the bottom surface of the lowermost layer of the PCB board (1), forming a closed magnetic circuit.

2. A transformer based on a PCB structure according to claim 1, characterized in that, An insulating film (5) is provided between adjacent PCB boards (1) and between the PCB board (1) and the iron core material (4).

3. A transformer based on a PCB structure according to claim 2, characterized in that, The through holes (12) are provided around the winding coil (3), and the insulating film (5) between adjacent PCB boards (1) does not block the through holes (12), while the insulating film (5) between the PCB board (1) and the core material (4) covers the through holes (12).

4. A transformer based on a PCB structure according to claim 1, characterized in that, The soft magnetic material (2) is selected from ferrite materials.

5. A transformer based on a PCB structure according to claim 1, characterized in that, The thickness of the soft magnetic material (2) is the same as the thickness of the PCB board (1).

6. A transformer based on a PCB structure according to claim 1, characterized in that, The insertion port (11) has a card interface (13) on its wall. The soft magnetic material (2) has a snap-fit ​​protrusion (22). The snap-fit ​​protrusion (22) is inserted into the insertion port (11) from the card interface (13). By rotating, the snap-fit ​​protrusion (22) is offset from the entrance of the card interface (13), thereby realizing the snap-fit ​​of the soft magnetic material (2).

7. A transformer based on a PCB structure according to claim 6, characterized in that, The soft magnetic material (2) has a material feeding groove (21) on its top surface.

8. A transformer based on a PCB structure according to claim 6 or 7, characterized in that, The card interface (13) is an L-shaped or N-shaped arc surface.

9. A transformer based on a PCB structure according to claim 1, characterized in that, The PCB board (1) is connected to power terminals, which are divided into two groups, each group consisting of a positive terminal and a negative terminal.

10. A transformer based on a PCB structure according to claim 9, characterized in that, A single PCB board (1) has several layers along the vertical direction, with the outermost layer having two sides divided into A and B. The winding coils (3) are provided between each layer and between the A and B sides. The PCB board (1) has conductive holes (10). The conductive holes of each layer in the PCB board are the conduction paths for the winding coils of each layer to be connected in series or in parallel. Conductive material (31) is provided in the conductive holes of each layer of the PCB board. The winding coils (3) between each layer of the PCB board (1) and between the A and B sides are connected in series or in parallel through the conductive material (31).

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