Transformer and insulation method thereof

Abstract

The transformer comprises a transformer framework, the transformer framework comprises a wrapping post, an upper limiting part and a lower limiting part which are integrally formed, a hollow through hole is formed in the middle of the wrapping post, the upper limiting part and the lower limiting part are arranged at the upper end and the lower end of the wrapping post respectively, and the upper limiting part and the lower limiting part are arranged in parallel; a primary coil and a secondary coil can be wound on the periphery of the wrapping post, an isolating layer is arranged between the primary coil and the secondary coil and adopts a reverse folding adhesive tape, a first side clamping structure is arranged on one side of the lower limiting part, a second side clamping structure is arranged on the opposite side of the lower limiting part, and the reverse folding adhesive tape is pasted at the joint of the wrapping post and the first side clamping structure. After the primary coil is wound, the reverse folding adhesive tape is reversely folded and then the secondary coil is wound; a reverse folding adhesive tape is pasted at the joint of the wrapping post and the second side clamping structure, the reverse folding adhesive tape is reversely folded after the primary coil is wound, and then the secondary coil is wound, so that primary and secondary isolation is realized. A plurality of transformers are automatically wound at the same time, and the production efficiency is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of transformers, in particular to a transformer and an insulation method of the transformer. BACKGROUND

[0002] In current transformer winding production, in order to improve electrical safety performance, a physical isolation structure is generally arranged at the winding link to increase the safety distance of the primary and secondary coils. The conventional process is to first complete the winding of the primary coil on the transformer framework, then wind the secondary coil, and then set a Teflon sleeve at the intersection contact part of the primary and secondary coils to achieve isolation. However, this insulation scheme using a Teflon sleeve has obvious drawbacks. On the one hand, the cost of Teflon material itself is relatively high, which will directly increase the overall production cost of the transformer. On the other hand, the matching sleeve machine usually only supports single-axis side winding operation mode and cannot realize multi-station synchronous processing, resulting in a significant reduction in the production efficiency of the winding process, which is difficult to adapt to the needs of large-scale production.

[0003] Therefore, it is necessary to improve the prior art. SUMMARY

[0004] The present application aims to at least solve one of the problems existing in the prior art, and one purpose of the present application is to provide a transformer and an insulation method of the transformer, which uses a reverse folding tape for insulation, not only reducing the manufacturing cost, but also improving the production efficiency.

[0005] The above-mentioned purpose is achieved by the following technical solutions:

[0006] A transformer, comprising a transformer framework, the transformer framework comprising an integrally formed winding column, an upper limiting part and a lower limiting part, the winding column being provided with a hollow through hole in the middle, the upper limiting part and the lower limiting part being respectively arranged at the upper and lower ends of the winding column, and the upper limiting part and the lower limiting part being arranged in parallel with each other;

[0007] The winding column can be wound with a primary coil and a secondary coil, and an isolation layer is arranged between the primary coil and the secondary coil, the isolation layer being a reverse folding tape, a first side clamping structure being arranged on one side of the lower limiting part, and a second side clamping structure being arranged on the opposite side, the reverse folding tape being pasted at the connection between the winding column and the first side clamping structure, the reverse folding tape being folded back after winding the primary coil and then winding the secondary coil;

[0008] The reverse folding tape is pasted at the connection between the winding column and the second side clamping structure, the reverse folding tape is folded back after winding the primary coil and then winding the secondary coil, so as to achieve primary-secondary isolation.

[0009] In some embodiments, the upper limit portion comprises a third side clamp structure and a fourth side clamp structure opposite to each other, the third side clamp structure is above the first side clamp structure, and the fourth side clamp structure is above the second side clamp structure.

[0010] In some embodiments, the first side clamp structure comprises a first pin head, a first wire clamping protrusion, and a second wire clamping protrusion, a plurality of the first pin heads are arranged and spaced apart by a first wire clamping groove, and the bottom of the plurality of the first pin heads is provided with a first pin.

[0011] The first wire clamping protrusion is arranged above the first pin head radially outward of the winding post, and a first protrusion groove is arranged between a plurality of the first wire clamping protrusions.

[0012] The second wire clamping protrusion is arranged at the bottom of the first pin head axially downward of the winding post, a second protrusion groove is arranged between a plurality of the second wire clamping protrusions, the second wire clamping protrusion is inside the first pin, and the second protrusion groove is matched with the first pin.

[0013] In some embodiments, the second side clamp structure comprises a second pin head and a second wire clamping groove, a plurality of the second pin heads are spaced apart by the second wire clamping groove, and the bottom of a plurality of the second pin heads is respectively provided with a second pin.

[0014] In some embodiments, the second side clamp structure is provided with a side edge pin head on one side, the side edge pin head is connected with the second pin head, and the bottom of the side edge pin head is provided with a side pin.

[0015] In some embodiments, the third side clamp structure comprises a first wire passing protrusion, a first rib plate, and a first reinforcing plate, the first rib plate is perpendicular to the lower limit portion, a groove is recessed in the middle of the first rib plate, the first wire passing protrusion is arranged on the groove radially of the winding post, a first limiting plate is arranged on the outer side of the first rib plate on both sides of the first wire passing protrusion respectively, and the first rib plate and the first limiting plate are perpendicular and are reinforced and connected by the first reinforcing plate.

[0016] In some embodiments, the fourth side clamp structure comprises a second wire passing protrusion, a second rib plate, a second limiting plate, and a second reinforcing plate, the second rib plate is perpendicular to the lower limit portion, the second wire passing protrusion is arranged on the outer side of the second rib plate, the second limiting plate is arranged on both sides of the second wire passing protrusion, and the second rib plate and the second limiting plate are perpendicular and are reinforced and connected by the second reinforcing plate.

[0017] In some embodiments, a first guide slope surface that is inclined from top to bottom is arranged in the first protrusion groove.

[0018] A second guide slope that slopes downwards is provided in the second wire slot.

[0019] The above objective is achieved through the following insulation method.

[0020] An insulation method for a transformer includes the following steps:

[0021] A: After the wire passes around the first pin, the primary coil is wound around the outer circumference of the winding post;

[0022] B: Apply the reverse folding tape to the connection between the primary coil and the first side clamp structure, so that part of the reverse folding tape covers the first pin plate;

[0023] C: After the wire passes around the second pin, a secondary coil is wound around the outer periphery of the winding post;

[0024] D: Fold the tape covering the first pin onto the secondary coil and then wrap it with insulating tape.

[0025] E: After the wire passes around the first pin, the primary coil is wound around the outer periphery of the winding post;

[0026] F: Apply the reverse folding tape to the connection between the primary coil and the second side clamp structure, so that part of the reverse folding tape covers the second pin plate;

[0027] G: After the wire passes around the first pin, the secondary coil is wound around the outer periphery of the winding post;

[0028] H: Fold the tape covering the second pin onto the secondary coil and then wrap it with insulating tape.

[0029] I: Cut the wire, wrap it with insulating tape again, and proceed to the next step.

[0030] Compared with the prior art, the present invention has at least the following beneficial effects:

[0031] The present invention proposes a transformer and a method for insulating the transformer, which uses tape for insulation and can simultaneously perform automated winding of multiple transformers, thereby reducing manufacturing costs and improving production efficiency. Attached Figure Description

[0033] Figure 1 This is a three-dimensional schematic diagram of the transformer in the embodiment (1);

[0034] Figure 2 This is a three-dimensional schematic diagram of the transformer in the embodiment (2);

[0035] Figure 3 This is a three-dimensional schematic diagram of the transformer in the embodiment (3);

[0036] Figure 4 This is a three-dimensional schematic diagram of the transformer in the embodiment (4);

[0037] Figure 5 This is a bottom view of the transformer in the embodiment.

[0038] In the diagram: 1. Winding post; 2. Upper limit position; 21. Third side clamp structure; 211. First thread guide protrusion; 212. First stiffening plate; 2121. Groove; 213. First reinforcing plate; 214. First limiting plate; 22. Fourth side clamp structure; 221. Second thread guide protrusion; 222. Second stiffening plate; 223. Second limiting plate; 224. Second reinforcing plate; 3. Lower limit position; 31. First side clamp structure; 311. First needle 312. First wire-locking protrusion; 313. Second wire-locking protrusion; 314. First wire-locking groove; 315. First pin; 316. First protrusion groove; 317. Second protrusion groove; 318. First guide slope; 32. Second side clamping structure; 321. Second pin platform; 322. Second wire-locking groove; 323. Second pin; 324. Side pin platform; 325. Side pin; 326. Second guide slope; 4. Through hole. Detailed Implementation

[0040] The following embodiments illustrate the present invention, but the present invention is not limited to these embodiments. Modifications to the specific embodiments of the present invention or equivalent substitutions for some technical features, without departing from the spirit of the present invention, should all be covered within the scope of the technical solutions claimed in the present invention.

[0041] like Figures 1 to 5 As shown, this embodiment provides a transformer, including a transformer frame. The transformer frame includes an integrally formed winding post 1, an upper limit part 2, and a lower limit part 3. The winding post 1 is provided with a hollow through hole 4 in the middle. The upper limit part 2 and the lower limit part 3 are respectively disposed at the upper and lower ends of the winding post 1, and the upper limit part 2 and the lower limit part 3 are arranged parallel to each other.

[0042] The winding post 1 can be wound with a primary coil and a secondary coil. An isolation layer is provided between the primary coil and the secondary coil. The isolation layer is made of reverse-folded tape. A first side clamp structure 31 is provided on one side of the lower limit part 3, and a second side clamp structure 32 is provided on the opposite side. Reverse-folded tape is pasted at the connection between the winding post 1 and the first side clamp structure 31. After the primary coil is wound, the reverse-folded tape is folded back and then wound with the secondary coil.

[0043] Apply reverse-folded tape at the connection between the winding post 1 and the second side clamp structure 32. After winding the primary coil, fold the reverse-folded tape back and then wind the secondary coil to achieve primary-secondary isolation.

[0044] The present invention proposes a transformer and a transformer insulation method, which uses reverse-folded tape for insulation and can simultaneously perform automated winding of multiple transformers, thereby reducing manufacturing costs and improving production efficiency.

[0045] Furthermore, the upper limit stop 2 includes a third side clamp structure 21 and a fourth side clamp structure 22 facing each other. The third side clamp structure 21 is above the first side clamp structure 31, and the fourth side clamp structure 22 is above the second side clamp structure 32. The upper limit stop 2, in conjunction with the limiting part 3, facilitates the fixing of the wire, reduces the number of times the wire is cut, and is beneficial for the realization of automated winding.

[0046] Furthermore, the first side clamp structure 31 includes a first pin platform 311, a first wire-holding protrusion 312 and a second wire-holding protrusion 313, and a first wire-holding groove 314 is provided between and spaced apart by the first pin platforms 311, and a first pin 315 is provided at the bottom of the first pin platforms 311.

[0047] A first wire-locking protrusion 312 is provided radially outward from the winding post 1 and above the first needle platform 311, and a first protrusion groove 316 is provided at intervals between a plurality of first wire-locking protrusions 312.

[0048] A second wire-clamping protrusion 313 is provided at the bottom of the first pin platform 311, axially downwards from the winding post 1. Second protrusion grooves 317 are spaced apart between several of the second wire-clamping protrusions 313. The second wire-clamping protrusions 313 are located inside the first pin 315, and the second protrusion grooves 317 cooperate with the first pin 315. The first side clamp structure 31 meets the needs of flexible wiring and functional expansion of the transformer, improving the transformer's application scenarios. The spaced second protrusion grooves 317 between the second wire-clamping protrusions 313 can, on the one hand, reduce the DC resistance loss of the coil and improve power transmission efficiency; on the other hand, it can form multiple heat dissipation channels, providing evenly distributed space and improving the transformer's heat dissipation effect.

[0049] Furthermore, the second side clamp structure 32 includes a second pin platform 321 and a second wire-holding groove 322. A plurality of second pin platforms 321 are spaced apart by the second wire-holding groove 322, and a second pin 323 is respectively provided at the bottom of the plurality of second pin platforms 321. The structural arrangement of the second side clamp structure 32 facilitates the shuttle connection of wires between the second side clamp structures 32.

[0050] Preferably, a side pin platform 324 is provided on one side of the second side clamp structure 32, the side pin platform 324 is connected to the second pin platform 321, and a side pin 325 is provided at the bottom of the side pin platform 324. The side pin platform 324 facilitates the connection of the transformer to other components as needed via the side pin 325.

[0051] Furthermore, the third side clamp structure 21 includes a first wire-passing protrusion 211, a first stiffening plate 212, and a first reinforcing plate 213. The first stiffening plate 212 is perpendicular to the lower limiting portion 3, and a groove 2121 is recessed in the middle of the first stiffening plate 212. The first wire-passing protrusion 211 is provided radially on the winding post 1 and on the groove 2121. First limiting plates 214 are respectively provided on the outer side of the first stiffening plate 212 and on both sides of the first wire-passing protrusion 211. The first stiffening plate 212 and the first limiting plate 214 are perpendicular and reinforcedly connected by the first reinforcing plate 213. The structural design of the third side clamp structure 21 facilitates the fixing of the wire to the third side clamp structure 21. It also facilitates the connection of the transformer with other components as needed.

[0052] Furthermore, the fourth side clamp structure 22 includes a second wire-passing protrusion 221, a second rib plate 222, a second limiting plate 223, and a second reinforcing plate 224. The second rib plate 222 is perpendicular to the lower limiting portion 3. The second wire-passing protrusion 221 is provided on the outer side of the second rib plate 222, and the second limiting plate 223 is provided on both sides of the second wire-passing protrusion 221. The second rib plate 222 and the second limiting plate 223 are perpendicular to each other and are reinforcedly connected by the second reinforcing plate 224. The structural design of the fourth side clamp structure 22 facilitates the fixing of the wire to the fourth side clamp structure 22.

[0053] Preferably, a first guide slope 318 inclined downwards is provided in the first protruding groove 316; and a second guide slope 326 inclined downwards is provided in the second wire clamping groove 322. The first guide slope 318 and the second guide slope 326 are provided to prevent wire displacement.

[0054] The above objective is achieved through the following insulation method.

[0055] An insulation method for a transformer includes the following steps:

[0056] A: After the wire passes around the first pin, the primary coil is wound around the outer circumference of the winding post;

[0057] B: Apply the reverse folding tape to the connection between the primary coil and the first side clamp structure, so that part of the reverse folding tape covers the first pin plate;

[0058] C: After the wire passes around the second pin, a secondary coil is wound around the outer periphery of the winding post;

[0059] D: Fold the tape covering the first pin onto the secondary coil and then wrap it with insulating tape.

[0060] E: After the wire passes around the first pin, the primary coil is wound around the outer periphery of the winding post;

[0061] F: Apply the reverse folding tape to the connection between the primary coil and the second side clamp structure, so that part of the reverse folding tape covers the second pin plate;

[0062] G: After the wire passes around the first pin, the secondary coil is wound around the outer periphery of the winding post;

[0063] H: Fold the tape covering the second pin onto the secondary coil and then wrap it with insulating tape.

[0064] I: Cut the wire, wrap it with insulating tape again, and proceed to the next step.

[0065] The above descriptions are merely some embodiments of the present invention. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A transformer, comprising a transformer frame, characterized in that, The transformer frame includes an integrally formed winding post (1), an upper limit part (2), and a lower limit part (3). The winding post (1) has a hollow through hole (4) in the middle. The upper limit part (2) and the lower limit part (3) are respectively located at the upper and lower ends of the winding post (1), and the upper limit part (2) and the lower limit part (3) are arranged parallel to each other. The winding post (1) can be wound with a primary coil and a secondary coil. An isolation layer is provided between the primary coil and the secondary coil. The isolation layer is made of reverse-folded tape. A first side clamp structure (31) is provided on one side of the lower limit part (3), and a second side clamp structure (32) is provided on the opposite side. Reverse-folded tape is pasted at the connection between the winding post (1) and the first side clamp structure (31). After winding the primary coil, the reverse-folded tape is folded back and then wound with the secondary coil. Apply reverse-fold tape at the connection between the winding post (1) and the second side clamp structure (32), wrap the primary coil, fold the reverse-fold tape back and then wrap the secondary coil to achieve primary and secondary isolation.

2. A transformer according to claim 1, characterized in that, The upper limit part (2) includes a third side clamp structure (21) and a fourth side clamp structure (22) facing each other. The third side clamp structure (21) is above the first side clamp structure (31), and the fourth side clamp structure (22) is above the second side clamp structure (32).

3. A transformer according to claim 2, characterized in that, The first side clamp structure (31) includes a first pin platform (311), a first wire-holding protrusion (312), and a second wire-holding protrusion (313). A first wire-holding groove (314) is provided between a plurality of first pin platforms (311) and is spaced apart therebetween. A first pin (315) is provided at the bottom of a plurality of first pin platforms (311). The first wire-locking protrusion (312) is provided radially outward from the winding post (1) and above the first needle platform (311), and a first protrusion groove (316) is provided at intervals between a plurality of the first wire-locking protrusions (312). A second wire-locking protrusion (313) is provided at the bottom of the first pin platform (311) axially downward on the winding post (1). A second protrusion groove (317) is provided between a plurality of second wire-locking protrusions (313). The second wire-locking protrusions (313) are located inside the first pin (315), and the second protrusion groove (317) cooperates with the first pin (315).

4. A transformer according to claim 3, characterized in that, The second side clamp structure (32) includes a second pin platform (321) and a second wire-holding groove (322). A plurality of second pin platforms (321) are spaced apart by the second wire-holding groove (322), and a second pin (323) is provided at the bottom of each of the plurality of second pin platforms (321).

5. A transformer according to claim 4, characterized in that, The second side clamp structure (32) has a side pin table (324) on one side, the side pin table (324) is connected to the second pin table (321), and the side pin table (324) has a side pin (325) at the bottom.

6. A transformer according to claim 2, characterized in that, The third side clamp structure (21) includes a first wire guide protrusion (211), a first stiffener plate (212), and a first reinforcing plate (213). The first stiffener plate (212) is perpendicular to the lower limiting part (3). A groove (2121) is recessed in the middle of the first stiffener plate (2121). The first wire guide protrusion (211) is provided on the groove (2121) in the radial direction of the winding post (1). A first limiting plate (214) is provided on the outer side of the first stiffener plate (212) and on both sides of the first wire guide protrusion (211). The first stiffener plate (212) and the first limiting plate (214) are perpendicular to each other and are reinforced and connected by the first reinforcing plate (213).

7. A transformer according to claim 2, characterized in that, The fourth side clamping structure (22) includes a second wire guide protrusion (221), a second stiffener (222), a second limiting plate (223), and a second reinforcing plate (224). The second stiffener (222) is perpendicular to the lower limiting part (3). The second wire guide protrusion (221) is provided on the outer side of the second stiffener (222). The second limiting plate (223) is provided on both sides of the second wire guide protrusion (221). The second stiffener (222) and the second limiting plate (223) are perpendicular to each other and are reinforcedly connected by the second reinforcing plate (224).

8. A transformer according to claim 4, characterized in that, A first guide slope (318) that slopes downward from top to bottom is provided in the first protrusion groove (316). A second guide slope (326) is provided in the second wire slot (322) that slopes downward from top to bottom.

9. An insulation method for a transformer, applicable to the transformer as described in any one of claims 1-8, characterized in that, Includes the following steps: A: After the wire passes around the first pin, the primary coil is wound around the outer circumference of the winding post; B: Apply the reverse folding tape to the connection between the primary coil and the first side clamp structure, so that part of the reverse folding tape covers the first pin plate; C: After the wire passes around the second pin, a secondary coil is wound around the outer periphery of the winding post; D: Fold the tape covering the first pin onto the secondary coil and then wrap it with insulating tape. E: After the wire passes around the first pin, the primary coil is wound around the outer periphery of the winding post; F: Apply the reverse folding tape to the connection between the primary coil and the second side clamp structure, so that part of the reverse folding tape covers the second pin plate; G: After the wire passes around the first pin, the secondary coil is wound around the outer periphery of the winding post; H: Fold the tape covering the second pin onto the secondary coil and then wrap it with insulating tape. I: Cut the wire, wrap it with insulating tape again, and proceed to the next step.

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