High-frequency transformer and assembling method thereof

Abstract

The invention discloses a high-frequency transformer and an assembling method thereof.The high-frequency transformer comprises a framework, the middle of the framework is cylindrical, a coil is wound around the middle of the framework, a lead is arranged at the end of the coil, a sleeve is arranged on the lead, wire connecting boxes are arranged on the two sides of the bottom of the framework, and a plurality of pins are arranged at the bottoms of the wire connecting boxes; each lead of the coil is connected with a corresponding pin, the coil is wrapped by a separation adhesive tape, a copper foil is wrapped between the separation adhesive tape and the coil, and a high-permeability magnetic core is mounted on the framework. According to the high-frequency transformer, the structure of the framework is improved, so that the leads can be directly welded with the pins before winding, the leads can be directly connected with the corresponding pin supports in the winding process, the problem that the leads and the pins are connected mistakenly is solved, meanwhile, the high-frequency transformer with the structure is convenient to assemble, and the cost is reduced. And the probability of errors in the assembly process of the high-frequency transformer is reduced.

Description

Technical Field

[0001] This invention relates to the field of transformer technology, specifically to a high-frequency transformer and its assembly method. Background Technology

[0002] High-frequency transformers are power transformers that operate at frequencies exceeding intermediate frequencies, primarily used in high-frequency switching power supplies. The manufacturing process of this type of transformer requires the assembly of various components. The structure of high-frequency transformers varies depending on their type and model, and the ease of assembly also differs considerably.

[0003] In the prior art, Chinese Patent Publication No. CN114093629B discloses a high-frequency transformer and its assembly method, including a winding frame, multi-strand wires, and a plug-in assembly. The winding frame has multiple strands of wire evenly wound around its center. Plug-in assemblies are inserted into several slots symmetrically opened on the upper part of the winding frame. The upper open inner wall of the plug-in assembly has a tin-plated portion, and the lower part of the plug-in assembly is flared. The inner wall of the plug-in assembly is uniformly coated with an adhesive layer. One end of the multi-strand wires is inserted through the center of the plug-in assembly. This high-frequency transformer and its assembly method, by inserting silver-plated copper sleeve plug-in assemblies into the slots of the winding frame, with the multi-strand wires simultaneously inserted within these plug-in assemblies, allows the plug-in assembly to effectively limit and enclose the expansion of the multi-strand wires during tinning. This not only saves on tin usage and improves the aesthetics after tinning, but also enhances current stability during later use, reduces production costs, and lowers the defect rate of the assembled product.

[0004] The aforementioned patent provides a common high-frequency transformer and its assembly method. Assembly methods vary depending on the structure of the high-frequency transformer. For multi-pin high-frequency transformers, the wires are often led out to the vicinity of the pins during winding before soldering. However, in practice, due to the large amount of winding work and the complexity of the operation, wire ends are easily tangled. This necessitates determining the corresponding pin for each lead before soldering. However, this process of determining the corresponding pin for each lead is time-consuming and severely impacts the production efficiency of high-frequency transformers. Summary of the Invention

[0005] The purpose of this invention is to provide a high-frequency transformer and its assembly method, which aims to improve the problem that in the existing high-frequency transformer, the leads are easily detached from the original lead slots during the winding process, resulting in messy lead ends and making it inconvenient to solder the leads to the pins later.

[0006] This invention is implemented as follows:

[0007] To achieve the above objectives, according to one aspect of the present invention, a high-frequency transformer is provided, comprising a frame, the frame being cylindrical in the middle, a coil wound around the middle of the frame, a lead wire provided at the end of the coil, a sleeve provided on the lead wire, junction boxes provided on both sides of the bottom of the frame, a plurality of pins provided at the bottom of the junction boxes, each lead wire of the coil being connected to a corresponding pin, a separating tape wrapped around the outside of the coil, copper foil wrapped between the separating tape and the coil, a high-permeability magnetic core mounted on the frame; a fixing tape wrapped around the outside of the high-permeability magnetic core for fixing the high-permeability magnetic core, and insulating tape wrapped in a cross shape between the fixing tape and the side of the coil, the insulating tape stably winding the high-permeability magnetic core and the coil together to ensure the stability of the entire high-frequency transformer.

[0008] Furthermore, the top and bottom ends of the frame are provided with limiting end plates for limiting the coil. The middle part of the frame is provided with a through hole for installing a high-permeability magnetic core. The connecting box is symmetrically arranged on both sides of the bottom of the frame, and the upper surface of the connecting box is provided with a connecting groove aligned with the position of each pin. The top of the pin is inserted into the connecting groove for connecting with the lead of the coil. The top two sides of the frame are symmetrically provided with limiting frames aligned with the connecting box.

[0009] Furthermore, the high-permeability magnetic core is composed of two splicing parts, which are L-shaped and arranged diagonally symmetrically. Each splicing part is provided with a post at the position aligned with the through hole, and the posts of the two splicing parts abut together.

[0010] According to a second aspect of the present invention, a method for assembling a high-frequency transformer is provided, specifically comprising the following steps:

[0011] S1. Material preparation: Prepare the frame, copper wire, high permeability magnetic core, copper foil, tape and soldering equipment required for assembling the high frequency transformer, and prepare a certain amount of bushings.

[0012] S2. Winding: Fix the skeleton on the winding workbench, put a sleeve on one end of the copper wire lead, and then insert the lead into the corresponding pin's connection slot. Use a soldering device to connect the lead to the pin inserted into the connection slot, and use insulating glue to firmly stick the copper wire into the connection slot. Then control the winding workbench to drive the skeleton to rotate, while the worker pulls the copper wire to guide it, ensuring that the copper wire can be evenly wound on the skeleton. After winding, put a sleeve on the other end of the copper wire lead and insert it into the corresponding pin's connection slot, and then solder it firmly.

[0013] S3. Copper foil wrapping: After winding, wrap copper foil around the outer side of the coil to reduce leakage inductance;

[0014] S4. Wrapping with tape: Use separating tape to wrap the copper foil and copper wire around the outside of the coil;

[0015] S5. Assemble the magnetic core: Install the two splicing parts of the high-permeability magnetic core onto the frame from the top and bottom of the frame respectively. Then, align the two high-permeability magnetic cores and wrap them with fixing tape. Finally, wrap the high-permeability magnetic core and coil with insulating tape.

[0016] S6. Impregnation: The assembled high-frequency transformer is placed in an iron pan, and the iron pan is placed in an impregnation tank for immersion. After immersion, it is dried and cooled.

[0017] S7. Labeling: Affix product labels to the outer surface of the high-frequency transformer;

[0018] S8. Electrical Testing: Perform inductance testing, turns testing, and high voltage testing on the high-frequency transformer. Once the tests are completed and the transformer passes the tests, it will be put into storage.

[0019] Furthermore, the winding workbench in step S2 includes a support platform, a drive assembly, a clamping assembly, and a tray. The drive assembly is installed in the middle of the support platform, the clamping assembly is installed on the top of the support platform and is positioned directly above the drive assembly, and a skeleton is installed between the clamping assembly and the drive assembly. A tray is installed at the bottom of the support platform and is used to place some commonly used tools.

[0020] Furthermore, each corner of the support platform is provided with a support leg, and a controller is provided at the top front of the support platform. A switch is provided in the middle of the controller, and the controller and the switch are used to control the drive component. A socket is provided at the bottom front of the support platform for mounting a tray. A first bearing is provided in the middle of the upper surface of the support platform for connecting to the drive component. A support plate is provided at the rear end of the support platform. The support plate is L-shaped, and a threaded hole is provided at the front end of the top of the support plate for connecting to the clamping component.

[0021] Furthermore, the drive assembly includes a motor and a support base. The motor is mounted on the inner top of the support platform, and one end of the motor that is in contact with the support platform is provided with multiple connecting feet for fixing the position of the motor. A wire is provided on the side of the motor, and a connector is provided at the end of the wire. The wire and the connector are used to connect to the controller. A drive shaft is provided at the output end of the motor. The drive shaft passes through the top of the support platform, and a plug groove is provided at the top of the drive shaft. The support base is mounted on the plug groove. A first limiting plate is provided on the top of the support base. A first positioning post is provided on the upper surface of the first limiting plate. The first limiting plate and the first positioning post are used to connect to the frame.

[0022] Furthermore, the clamping assembly includes a drive screw and a pressure head. The top of the drive screw is provided with a rotating handle, and the bottom of the drive screw is provided with a connecting shaft. The top of the pressure head is provided with a second bearing, which is rotatably connected to the connecting shaft. The bottom of the pressure head is provided with a second limiting plate, and the middle of the bottom surface of the second limiting plate is provided with a second positioning post. The second limiting plate and the second positioning post are used to connect with the top of the frame.

[0023] Furthermore, in step S1, the skeleton to be wound is installed at the motor output end. The motor drives the skeleton to rotate at high speed, thereby achieving the purpose of rapid winding. During winding, workers or machines need to guide the copper wire to ensure that it is wound in the predetermined direction to avoid the wound copper wire not meeting production requirements. In step S3, in addition to the solder joints being flattened, the starting edge of the copper foil should avoid pressing on the corners of the skeleton. It must start from the center of the skeleton to prevent short circuits caused by the second layer of copper foil puncturing the tape due to compression. At the same time, it is necessary to ensure that the copper foil is not damaged when wrapping it. Wrapping ensures that all copper wires are wrapped inside the copper foil. In step S4, the tape must be stretched taut and flat, without being flipped up or punctured, and without exposing the copper wires. The outermost layer of tape should not be wrapped too tightly to avoid affecting the appearance of the product. At the same time, the tape should be wrapped evenly in all positions, and each layer of tape should be firmly adhered to avoid air between the tapes, which can easily cause the tape to break. In step 6, after placing the iron pan in the impregnation tank, a vacuum impregnation machine is used to remove air, and insulating varnish is placed inside the impregnation tank. Then, the vacuum is continuously drawn and broken 3-4 times, and impregnation is carried out for 12-18 minutes. For drying, the oven temperature needs to be adjusted to 80°C. After preheating for one hour, the temperature is adjusted to 100°C. After baking at 100°C for two hours, the temperature is adjusted to 120°C and dried for another four hours. Then, the dried product is cooled down by a fan. After the product has cooled down, samples are unpacked to confirm whether it is qualified.

[0024] Furthermore, in step 7, before affixing the label, it is necessary to check whether the high-permeability magnetic core of the product has any damaged areas, whether the tape has any punctures, and whether the sleeve is too short. If any of the above problems occur, they need to be repaired. If the product cannot be repaired, it needs to be scrapped. At the same time, it is necessary to ensure that no residual adhesive remains on the surface of the iron core, so as to prevent the transformer from not being able to be flatly attached to the PCB board.

[0025] Compared with the prior art, the beneficial effects of the present invention are:

[0026] 1. This invention improves the structure of the frame, allowing the leads to be directly soldered to the pins before winding. This ensures that the leads can be directly connected to the corresponding pin supports during the winding process, thus avoiding the problem of incorrect connection between the leads and the pins. At the same time, this structure makes the high-frequency transformer easier to assemble, reducing the probability of errors during the assembly process.

[0027] 2. The high-permeability magnetic core of the present invention is wrapped with a layer of fixing tape. The fixing tape can make the structure of the high-permeability magnetic core, coil and frame sufficiently stable, and ensure that the entire high-frequency transformer structure is sufficiently stable.

[0028] 3. The winding worktable provided by this invention can stably clamp the bobbin of a high-frequency transformer and drive the bobbin to rotate. The motor of the winding worktable is a variable frequency motor, which can also adjust and control the rotation speed of the bobbin. The clamping assembly of the winding worktable has the advantage of adjustable clamping height, which is convenient for clamping bobbins of different heights and has the advantage of strong applicability. Attached Figure Description

[0029] Figure 1 This is a three-dimensional structural schematic diagram of the high-frequency transformer of the present invention;

[0030] Figure 2 This is a schematic diagram of the skeleton structure of the present invention;

[0031] Figure 3 This is a schematic diagram of the high-permeability magnetic core of the present invention;

[0032] Figure 4 This is a flowchart of the high-frequency transformer assembly method of the present invention;

[0033] Figure 5 This is a schematic diagram of the winding worktable of the present invention;

[0034] Figure 6 This is a schematic diagram of the support platform of the present invention;

[0035] Figure 7 This is a schematic diagram of the structure of the driving component of the present invention;

[0036] Figure 8 This is a flowchart of the clamping component of the present invention.

[0037] In the diagram: 1. Frame; 11. Limiting end plate; 12. Perforation; 13. Limiting frame; 14. Junction box; 15. Connecting groove; 16. Pin; 2. Coil; 3. Separating tape; 4. High-permeability magnetic core; 41. Splicing part; 42. Insert post; 5. Fixing tape; 6. Insulating tape; 7. Support platform; 71. Support leg; 72. Controller; 73. Switch; 74. Socket; 75. First bearing; 76. Support plate; 77. Threaded hole; 8. Drive components: 81. Motor; 811. Connecting foot; 812. Drive shaft; 813. Insertion slot; 814. Wire; 815. Connector; 82. Support; 821. First limiting plate; 822. First positioning post; 9. Pressing assembly; 91. Drive screw; 911. Connecting shaft; 912. Rotary handle; 92. Pressure head; 921. Second limiting plate; 922. Second positioning post; 923. Second bearing; 10. Tray. Detailed implementation method:

[0038] The following description, in conjunction with the accompanying drawings and specific embodiments, provides further details:

[0039] Example 1

[0040] This embodiment provides a high-frequency transformer, such as Figure 1 and Figure 2 As shown, the transformer includes a frame 1, which is cylindrical in the middle. A coil 2 is wound around the middle of the frame 1, and leads are provided at the ends of the coil 2. Sleeves are provided on the leads to ensure that the copper wires are insulated. Connection boxes 14 are located on both sides of the bottom of the frame 1. Multiple pins 16 are provided at the bottom of the connection boxes 14. Each lead of the coil 2 is connected to a corresponding pin 16. This structure facilitates the connection between the copper wires and the pins 16, and also facilitates the connection between the pins 16 and the PCB board. A separating tape 3 is wrapped around the outside of the coil 2 to insulate the surface of the high-frequency transformer. Copper foil is wrapped between the separating tape 3 and the coil 2. A high-permeability magnetic core 4 is mounted on the frame 1. The high-permeability magnetic core 4, together with the coil 2, functions as a transformer. The high-permeability magnetic core 4 is wrapped with fixing tape 5 to fix the high-permeability magnetic core 4. The high-permeability magnetic core 4 and the coil 2 are wrapped with insulating tape 6 in a cross shape with fixing tape 5. The insulating tape 6 stably wraps the high-permeability magnetic core 4 and the coil 2 together to ensure the stability of the entire high-frequency transformer.

[0041] like Figure 2As shown, the top and bottom of the frame 1 are provided with limiting end plates 11 for limiting the coil 2. The middle of the frame 1 is provided with a through hole 12 for installing the high permeability magnetic core 4. The connecting box 14 is symmetrically arranged on both sides of the bottom of the frame 1, and the upper surface of the connecting box 14 is provided with a connecting groove 15 aligned with the position of each pin 16. The top of the pin 16 is inserted into the connecting groove 15 for connecting with the lead wire of the coil 2. The top two sides of the frame 1 are symmetrically provided with limiting frames 13, which are aligned with the connecting box 14. The limiting frames 13, together with the connecting box, can limit the high permeability magnetic core 4, ensuring the stable installation and use of the high permeability magnetic core 4.

[0042] like Figure 3 As shown, the high-permeability magnetic core 4 is composed of two splicing parts 41. The splicing parts 41 are L-shaped and the two splicing parts 41 are arranged diagonally symmetrically. Each splicing part 41 is provided with a post 42 at the position aligned with the through hole 12. The posts 42 of the two splicing parts 41 abut together. The high-permeability magnetic core 4 with this structure can be well matched with the coil 2 for voltage transformation, which facilitates the use of the entire high-frequency transformer.

[0043] Example 2

[0044] This embodiment provides a method for assembling a high-frequency transformer, such as... Figure 4 As shown, the specific steps of this assembly method are as follows:

[0045] S1. Material preparation: Prepare the frame, copper wire, high-permeability magnetic core, copper foil, tape, and soldering equipment for assembling the high-frequency transformer, and prepare a certain amount of bushings; install the frame to be wound on the motor output end, and drive the frame to rotate at high speed through the motor to achieve the purpose of rapid winding. During winding, workers or machines need to guide the copper wire to ensure that the copper wire is generated in the predetermined direction, so as to avoid the wound copper wire not meeting the production requirements.

[0046] S2. Winding: Fix the skeleton on the winding workbench, put a sleeve on one end of the copper wire lead, and then insert the lead into the corresponding pin's connecting slot. Use a soldering device to connect the lead to the pin inserted into the connecting slot, and use insulating glue to firmly stick the copper wire into the connecting slot. Then, control the winding workbench to drive the skeleton to rotate, while the worker pulls the copper wire to guide it, ensuring that the copper wire can be evenly wound on the skeleton. After winding, put a sleeve on the other end of the copper wire lead and insert it into the corresponding pin's connecting slot, and then solder it firmly.

[0047] S3. Copper Foil Wrapping: After winding, wrap the outer side of the coil with copper foil. The copper foil acts as a shield to reduce leakage inductance. In addition to flattening the solder joints, the starting edge of the copper foil should avoid pressing on the corner of the frame. It should start from the center of the frame to prevent the second layer of copper foil from puncturing the tape due to compression and forming a short circuit. At the same time, ensure that the copper foil is not damaged when wrapping. The wrapping is to ensure that all copper wires are wrapped inside the copper foil.

[0048] S4. Wrapping with tape: Wrap a layer of separating tape around the coil to cover both the copper foil and the copper wire. The tape must be stretched taut and flat, without being flipped up or punctured, and the copper wire must not be exposed. The outermost layer of tape should not be wrapped too tightly to avoid affecting the appearance of the product. At the same time, the tape should be wrapped evenly in all positions, and each layer of tape should be firmly adhered to avoid air between the tapes, which could easily cause the tape to break.

[0049] S5. Assemble the magnetic core: Install the two splicing parts of the high-permeability magnetic core onto the frame from the top and bottom of the frame respectively. Then, align the two high-permeability magnetic cores and wrap them with fixing tape. Finally, wrap the high-permeability magnetic core and coil with insulating tape.

[0050] S6. Impregnation: Place the assembled high-frequency transformer in an iron pan, and then place the iron pan in an impregnation tank for immersion. After immersion, dry and cool. After the iron pan is placed in the impregnation tank, use a vacuum impregnation machine to remove air and put insulating varnish inside the impregnation tank. Then continuously evacuate the vacuum and break the vacuum 3-4 times. Impregnate for 12-18 minutes. For drying, adjust the oven temperature to 80℃, then preheat for one hour and then adjust the temperature to 100℃. Bake at 100℃ for two hours and then adjust the temperature to 120℃ for another four hours. After drying, use a fan to accelerate the cooling of the product. After the product has cooled down, unpack samples to confirm whether it is qualified.

[0051] S7. Labeling: Before labeling, check whether the high-permeability magnetic core of the product has any damage, whether the tape has any punctures, and whether the sleeve is too short. If any of the above problems are found, they need to be repaired. If the product cannot be repaired, it needs to be scrapped. At the same time, ensure that there is no residual glue on the surface of the iron core to prevent the transformer from not being able to be flat against the PCB board. Affix the product label to the outer surface of the high-frequency transformer.

[0052] S8. Electrical Testing: Perform inductance testing, turns testing, and high voltage testing on the high-frequency transformer. Once the tests are completed and the transformer passes the tests, it will be put into storage.

[0053] In summary, this application improves the structure of the frame compared to the prior art, allowing the leads to be directly soldered to the pins in the early stages of winding. This ensures that the leads can be directly connected to the corresponding pin supports during the winding process, avoiding the problem of incorrect connection between the leads and pins. At the same time, this structure makes the high-frequency transformer easier to assemble and reduces the probability of problems occurring during the assembly process.

[0054] Example 3

[0055] This embodiment provides the winding workbench used in Embodiment 2, such as... Figure 4 and Figure 5 As shown, the winding workbench includes a support platform 7, a drive assembly 8, a clamping assembly 9, and a tray 10. The drive assembly 8 is installed in the middle of the support platform 7, and is used to rotate the bobbin 1, thereby facilitating the winding of copper wire onto the bobbin 1. The clamping assembly 9 is installed on the top of the support platform 7, and is positioned directly above the drive assembly 8. The space between the clamping assembly 9 and the drive assembly 8 is used to install the bobbin 1. This structure facilitates the fixing of the bobbin 1 and also makes it easy to disassemble and use the bobbin 1. A tray 10 is installed at the bottom of the support platform 7, and the tray 10 is used to place some commonly used tools.

[0056] like Figure 6 As shown, the support platform 7 has feet 71 at each corner of its bottom surface, which allows the entire winding workbench to be placed stably on the ground. A controller 72 is located at the top front of the support platform 7, with a switch 73 in the center. The controller 72 and switch 73 work together to control the drive assembly 8, facilitating its operation and use. A socket 74 is located at the bottom front of the support platform 7 for mounting the tray 10, facilitating its assembly and disassembly. A first bearing 75 is located in the center of the upper surface of the support platform 7, connecting to the drive assembly 8. A support plate 76 is located at the rear end of the support platform 7. The support plate 76 is L-shaped, and a threaded hole 77 is located at the front top of the support plate 76 for connecting to the clamping assembly 9, allowing the clamping assembly 9 to move up and down to clamp the frame 1.

[0057] like Figure 7As shown, the drive assembly 8 includes a motor 81 and a support 82. The motor 81 is mounted on the top inner side of the support platform 7, and multiple connecting feet 811 are provided at one end of the motor 81 that is in contact with the support platform 7 to fix the position of the motor 81 and ensure that the motor 81 is stable inside the support platform 7. A wire 814 is provided on the side of the motor 81, and a connector 815 is provided at the end of the wire 814. The wire 814 and the connector 815 are used to connect to the controller 72, so that the motor 81 can be controlled by the controller 72. A drive shaft 812 is provided at the output end of the motor 81. The drive shaft 812 passes through the top of the support platform 7, and a plug groove 813 is provided at the top end of the drive shaft 812. The support 82 is mounted on the plug groove 813. The drive shaft 812 is used to drive the support 82 to rotate, thereby driving the frame 1 to rotate through the support 82. The support 82 is provided with a first limiting plate 821 on its top, and a first positioning post 822 is provided on the upper surface of the first limiting plate 821. The first limiting plate 821 and the first positioning post 822 are used to connect with the frame 1.

[0058] like Figure 8 As shown, the clamping assembly 9 includes a drive screw 91 and a pressure head 92. The drive screw 91, in conjunction with the pressure head 92, is used to clamp the frame 1 onto the support 82. A rotating handle 912 is provided at the top of the drive screw 91 to facilitate rotation. A connecting shaft 911 is provided at the bottom of the drive screw 91, and a second bearing 923 is provided at the top of the pressure head 92. The second bearing 923 is rotatably connected to the connecting shaft 911, facilitating the rotatable connection between the pressure head 92 and the drive screw 91. A second limiting plate 921 is provided at the bottom of the pressure head 92, and a second positioning post 922 is provided in the middle of the bottom surface of the second limiting plate 921. The second limiting plate 921 and the second positioning post 922 are used to connect to the top of the frame 1, thereby ensuring the stability of the frame 1.

[0059] The winding worktable provided in this embodiment can stably clamp the bobbin 1 and drive it to rotate. The motor 81 of the winding worktable is a variable frequency motor, which can also adjust and control the rotation speed of the bobbin 1. The clamping assembly 9 of the winding worktable has the advantage of adjustable clamping height, which is convenient for clamping bobbins 1 of different heights and has the advantage of strong applicability.

[0060] The above are merely preferred embodiments of the present invention and are not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A high-frequency transformer, comprising a frame (1), characterized in that, The frame (1) is cylindrical in the middle, and a coil (2) is wound around the middle of the frame (1). A lead wire is provided at the end of the coil (2), and a sleeve is provided on the lead wire. A junction box (14) is provided on both sides of the bottom of the frame (1). A plurality of pins (16) are provided at the bottom of the junction box (14). Each lead wire of the coil (2) is connected to the corresponding pin (16). A separator tape (3) is wrapped around the outside of the coil (2). Copper foil is wrapped between the separator tape (3) and the coil (2). A high-permeability magnetic core (4) is installed on the frame (1). A fixing tape (5) is wrapped around the outside of the high-permeability magnetic core (4) to fix the high-permeability magnetic core (4). The high-permeability magnetic core (4) and the side of the coil (2) are wrapped with insulating tape (6) in a cross shape with the fixing tape (5). The insulating tape (6) stably winds the high-permeability magnetic core (4) and the coil (2) together to ensure the stability of the entire high-frequency transformer.

2. A high-frequency transformer according to claim 1, characterized in that, The frame (1) is provided with limit plates (11) at the top and bottom for limiting the coil (2). The frame (1) is provided with a through hole (12) in the middle for installing a high-permeability magnetic core (4). The connecting box (14) is symmetrically arranged on both sides of the bottom of the frame (1). The upper surface of the connecting box (14) is provided with a connecting groove (15) aligned with the position of each pin (16). The top of the pin (16) is inserted into the connecting groove (15) for connecting to the lead wire of the coil (2). The frame (13) is symmetrically arranged on both sides of the top of the frame (1) and is aligned with the connecting box (14).

3. A high-frequency transformer according to claim 2, characterized in that, The high-permeability magnetic core (4) is composed of two splicing parts (41). The splicing parts (41) are L-shaped and the two splicing parts (41) are arranged diagonally symmetrically. Each splicing part (41) is provided with a post (42) at the position aligned with the through hole (12). The posts (42) of the two splicing parts (41) abut together.

4. A method for assembling a high-frequency transformer, used for assembling the high-frequency transformer as described in claim 3, characterized in that, Specifically, the following steps are included: S1. Material preparation: Prepare the frame, copper wire, high permeability magnetic core, copper foil, tape and soldering equipment required for assembling the high frequency transformer, and prepare a certain amount of bushings. S2. Winding: Fix the skeleton on the winding workbench, put a sleeve on one end of the copper wire lead, and then insert the lead into the corresponding pin's connection slot. Use a soldering device to connect the lead to the pin inserted into the connection slot, and use insulating glue to firmly stick the copper wire into the connection slot. Then control the winding workbench to drive the skeleton to rotate, while the worker pulls the copper wire to guide it, ensuring that the copper wire can be evenly wound on the skeleton. After winding, put a sleeve on the other end of the copper wire lead and insert it into the corresponding pin's connection slot, and then solder it firmly. S3. Copper foil wrapping: After winding, wrap copper foil around the outer side of the coil to reduce leakage inductance; S4. Wrapping with tape: Use separating tape to wrap the copper foil and copper wire around the outside of the coil; S5. Assemble the magnetic core: Install the two splicing parts of the high-permeability magnetic core onto the frame from the top and bottom of the frame respectively. Then, align the two high-permeability magnetic cores and wrap them with fixing tape. Finally, wrap the high-permeability magnetic core and coil with insulating tape. S6. Impregnation: The assembled high-frequency transformer is placed in an iron pan, and the iron pan is placed in an impregnation tank for immersion. After immersion, it is dried and cooled. S7. Labeling: Affix product labels to the outer surface of the high-frequency transformer; S8. Electrical Testing: Perform inductance testing, turns testing, and high voltage testing on the high-frequency transformer. Once the tests are completed and the transformer passes the tests, it will be put into storage.

5. A high-frequency transformer assembly method according to claim 4, characterized in that, The winding workbench in step S2 includes a support platform (7), a drive assembly (8), a clamping assembly (9), and a tray (10). The drive assembly (8) is installed in the middle of the support platform (7). The clamping assembly (9) is installed on the top of the support platform (7) and is located directly above the drive assembly (8). The frame (1) is installed between the clamping assembly (9) and the drive assembly (8). The tray (10) is installed at the bottom of the support platform (7).

6. The high-frequency transformer assembly method according to claim 5, characterized in that, The support platform (7) is provided with feet (71) at the bottom corners, and a controller (72) is provided at the top front of the support platform (7). A switch (73) is provided in the middle of the controller (72). The controller (72) and the switch (73) are used to control the drive assembly (8). A socket (74) is provided at the bottom front of the support platform (7). The socket (74) is used to install the tray (10). A first bearing (75) is provided in the middle of the upper surface of the support platform (7). The first bearing (75) is used to connect with the drive assembly (8). A support plate (76) is provided at the rear end of the support platform (7). The support plate (76) is L-shaped, and a threaded hole (77) is provided at the front end of the top of the support plate (76) for connecting with the clamping assembly (9).

7. A high-frequency transformer assembly method according to claim 6, characterized in that, The drive assembly (8) includes a motor (81) and a support (82). The motor (81) is mounted on the inner top of the support platform (7), and one end of the motor (81) that is in contact with the support platform (7) is provided with multiple connecting feet (811) for fixing the position of the motor (81). A wire (814) is provided on the side of the motor (81), and a connector (815) is provided at the end of the wire (814). The wire (814) and the connector (815) are used to connect to the controller (72). The output end of the machine (81) is provided with a drive shaft (812), which passes through the top of the support platform (7). The top end of the drive shaft (812) is provided with a plug groove (813), and the support seat (82) is installed on the plug groove (813). The top of the support seat (82) is provided with a first limiting plate (821), and the upper surface of the first limiting plate (821) is provided with a first positioning post (822). The first limiting plate (821) and the first positioning post (822) are used to connect with the frame (1).

8. A high-frequency transformer assembly method according to claim 5, characterized in that, The pressing component (9) includes a driving screw rod (91) and a pressing head (92). A rotating handle (912) is provided at the top end of the driving screw rod (91), and a connecting shaft (911) is provided at the bottom end of the driving screw rod (91). A second bearing (923) is provided at the top of the pressing head (92), and the second bearing (923) is rotatably connected to the connecting shaft (911). A second limiting plate (921) is provided at the bottom of the pressing head (92), and a second positioning column (922) is provided in the middle of the bottom surface of the second limiting plate (921). The second limiting plate (921) and the second positioning column (922) are used to connect to the top end of the skeleton (1).

9. A high-frequency transformer assembly method according to claim 5, characterized in that, In the step S1, the skeleton to be wound is installed at the output end of the motor, and the motor is used to drive the skeleton to rotate at a high speed, so as to achieve the purpose of rapid winding. During winding, it is necessary for workers or machines to guide the copper wire to ensure that the copper wire is wound according to the predetermined direction to avoid the wound copper wire not meeting the production requirements; in the step S3, except that the copper foil must be flattened at the welding point, the starting winding edge of the copper foil should avoid being pressed at the corner of the skeleton and must start winding from the center of the skeleton to prevent the second layer of copper foil from piercing the adhesive tape due to extrusion with the first layer and forming a short circuit. At the same time, when wrapping the copper foil, it is necessary to ensure that the copper foil does not break, and the wrapping is to ensure that all copper wires are wrapped inside the copper foil; in the step S4, the tape must be tightened and wrapped flat, not turned up and pierced, and no copper wire should be exposed. The outermost tape should not be wrapped too tightly to avoid affecting the appearance of the product. At the same time, when wrapping the tape, each position of the tape needs to be wound evenly, and each layer of tape needs to be firmly pasted to avoid air between the tapes, which is likely to cause the tape to break; in the step 6, after placing the iron plate in the impregnation tank, it is necessary to use a vacuum impregnation machine to evacuate, and put insulating paint in the impregnation tank, then continuously evacuate and break the vacuum 3 - 4 times, impregnate for 12 min - 18 min. For drying, the temperature of the oven needs to be adjusted to 80 °C, then preheat for one hour and then adjust the temperature to 100 °C. After baking at 100 °C for two hours, adjust the temperature to 120 °C and dry for another four hours. Then, use a fan to accelerate the cooling of the dried product. After the product is cooled, disassemble the sample to confirm whether it is qualified.

10. A high-frequency transformer assembly method according to claim 9, characterized in that, In the step 7, before pasting the label, it is necessary to confirm whether there are damaged positions on the high-permeability core of the product, whether the tape is pierced, and whether the sleeve is too short. If so, it needs to be repaired.

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