Low temperature transformer and method of manufacturing the same

Abstract

This invention discloses a low-temperature transformer and its manufacturing method. The low-temperature transformer includes a frame, multiple sets of coils wound on the frame, and a magnetic core assembled with the frame. The key feature is that an infrared nano-heat dissipation film is attached between the turns and / or layers and / or on the surface of each set of coils, and an infrared nano-heat dissipation film is attached to the surface of the magnetic core. The infrared nano-heat dissipation film is an NIRC infrared nano-heat dissipation film with a far-infrared emissivity of up to 0.986. This invention, by attaching an infrared nano-heat dissipation film to the core heat-generating area of ​​the transformer, dissipates the temperature of the core heat-generating area via infrared radiation, constructing a multi-dimensional heat dissipation network. This achieves synergistic optimization of heat dissipation and insulation performance, while reducing production costs. It effectively solves the problems of unreasonable heat dissipation structure, obstructed heat conduction paths, difficulty in balancing insulation and heat dissipation, and high processing costs in existing transformer technologies.

Description

Technical Field

[0001] This invention relates to the field of transformer technology, specifically to a low-temperature transformer and its manufacturing method. Background Technology

[0002] As a core energy conversion component in power transmission networks and various electronic devices (such as PD chargers, AC-DC power modules, and industrial control equipment), the transformer's efficiency and thermal stability directly determine the overall performance and reliability of the equipment. During transformer operation, Joule losses occur in the windings due to the resistive effect when current flows through them, and core losses occur in the magnetic core due to hysteresis and eddy current effects under the influence of an alternating magnetic field. Both types of losses are continuously released as heat.

[0003] With the rapid development of electronic devices towards miniaturization and high power density, the installation space for transformers has been significantly reduced, and the heat dissipation environment has become increasingly harsh. If the generated heat cannot be dissipated in time, the internal temperature of the transformer will continue to rise: on the one hand, excessively high winding temperatures will accelerate the aging and embrittlement of the enameled wire insulation layer, and may even cause insulation breakdown, severely shortening the service life of the transformer; on the other hand, once the core temperature exceeds the threshold, its permeability will decrease significantly, leading to a further increase in hysteresis loss and eddy current loss, forming a vicious cycle of "heat generation - increased loss - even higher temperature," which not only reduces the transformer's energy conversion efficiency, but may also trigger the equipment's overheat protection, affecting the normal operation of the entire machine, and in extreme cases, may even cause fires and other safety hazards due to localized overheating.

[0004] Existing transformer heat dissipation solutions have many limitations: traditional solutions often rely on a single heat dissipation structure (such as external heat sinks or thermally conductive silicone fillers), resulting in fragmented heat dissipation path designs. Heat tends to accumulate between winding turns, between layers, and in the contact gaps between the magnetic core and the frame, leading to low thermal conductivity. Some solutions, in an effort to improve heat dissipation, blindly increase the number of heat sinks or use expensive materials with high thermal conductivity, which not only significantly increases material costs and production energy consumption but also occupies more installation space, contradicting the trend towards miniaturized equipment. At the same time, most heat dissipation materials and insulation materials are independent of each other, requiring additional auxiliary components such as Mylar sheets and insulating tape to achieve electrical isolation. This increases the complexity of the manufacturing process and may further hinder heat transfer due to gaps in component assembly, making it difficult to achieve synergistic optimization of heat dissipation and insulation performance.

[0005] In summary, existing transformers suffer from increasingly prominent problems such as unreasonable heat dissipation structures, obstructed heat conduction paths, difficulty in balancing insulation and heat dissipation, and high manufacturing costs, making them unable to meet the core requirements of modern electronic equipment for efficient heat dissipation, low loss, miniaturization, and low cost. Therefore, there is an urgent need to develop a low-temperature transformer with excellent heat dissipation, lower losses, controllable costs, and a compact structure. Summary of the Invention

[0006] To overcome the problems of unreasonable heat dissipation structure, obstructed heat conduction path, difficulty in balancing insulation and heat dissipation, and high processing cost in existing transformer technologies, this invention provides a low-temperature transformer and its preparation method. By attaching an infrared nano heat dissipation film to the core heat-generating area of ​​the transformer, a full-dimensional heat dissipation network is constructed, achieving synergistic optimization of heat dissipation and insulation performance while reducing production costs.

[0007] The technical solution of this invention is as follows: On one hand, the present invention provides a low-temperature transformer, including a frame, multiple sets of coils wound on the frame, and a magnetic core assembled with the frame, wherein each set of coils has an infrared nano heat dissipation film attached between turns and / or between layers and / or on the surface, and the surface of the magnetic core is attached with an infrared nano heat dissipation film.

[0008] As a preferred embodiment of the present invention, an infrared nano heat dissipation film is attached between the magnetic core and the skeleton.

[0009] As a preferred embodiment of the present invention, the infrared nano heat dissipation film comprises a nano heat dissipation material layer, an aluminum foil layer, and an adhesive coating arranged sequentially from top to bottom.

[0010] As a preferred embodiment of the present invention, the width of the infrared nano heat dissipation film attached between the coil turns is the same as the turn spacing.

[0011] As a preferred embodiment of the present invention, the width of the infrared nano heat dissipation film attached to the surface of the coil is the same as the height of the winding cavity of the skeleton.

[0012] As a preferred embodiment of the present invention, the width of the infrared nano heat dissipation film attached to the transverse or longitudinal surface of the magnetic core is the same as the width of the corresponding surface.

[0013] On the other hand, the present invention provides a method for preparing a low-temperature transformer as described in any of the above embodiments, comprising the following steps: The coils are wound sequentially on the frame; After each set of coils is wound, at least one second infrared nano heat dissipation film is attached to the surface. After assembling the magnetic core with the coil-wound frame, at least one ring of third infrared nano heat dissipation film is attached to the transverse surface of the magnetic core, and at least one ring of fourth infrared nano heat dissipation film is attached to the longitudinal surface of the magnetic core.

[0014] As a preferred embodiment of the present invention, the width of the second infrared nano heat dissipation film is the same as the height of the winding cavity of the skeleton.

[0015] As a preferred embodiment of the present invention, the width of the third infrared nano heat dissipation film is the same as the width of the transverse surface of the magnetic core, and the width of the fourth infrared nano heat dissipation film is the same as the width of the longitudinal surface of the magnetic core.

[0016] As a preferred embodiment of the present invention, when winding a coil with a turn spacing, a first infrared nano heat dissipation film is attached between the coil turns.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. By attaching infrared nano heat dissipation films between coil turns, on the surface, and in the core area, a fully enclosed heat dissipation network is constructed inside the coil, on the coil surface, and in the core as a whole. This removes heat loss from the source, effectively reducing the overall temperature of the transformer and avoiding the accumulation of local hot spots and vicious cycles. 2. The infrared nano heat dissipation film adopts NIRC infrared nano heat dissipation film, with a far-infrared emissivity of up to 0.986. It has both high thermal conductivity and high insulation, replacing the traditional combination design of insulating tape and heat dissipation components. It eliminates thermal resistance caused by component assembly gaps, avoids electrical interference, and meets safety certification requirements. 3. Improved heat dissipation efficiency can relax the working magnetic flux density of the magnetic core, reduce the number of winding coils, save copper wire, reduce material costs, reduce the space occupied by the coil, and further improve the power density of the power supply. 4. The adhesive-backed film design simplifies the installation process, allowing winding and film application to proceed simultaneously, improving production efficiency; the film helps to fix the coil and magnetic core, reducing structural loosening caused by vibration and extending the transformer's service life. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a front view of a low-temperature transformer according to an embodiment of the present invention; Figure 2 This is a side view of a low-temperature transformer according to an embodiment of the present invention; Figure 3 This is a top view of a low-temperature transformer according to an embodiment of the present invention; Figure 4 This is a front view of a cryogenic transformer with the infrared nano heat dissipation film removed from the magnetic core surface in one embodiment of the present invention. Figure 5 This is a front view of a low-temperature transformer without an infrared nano heat dissipation film in one embodiment of the present invention.

[0020] In the diagram, 1. Skeleton; 2. Coil; 3. Magnetic core; 4. Infrared nano heat dissipation film. Detailed Implementation

[0021] To make the technical problems, technical solutions, and beneficial effects of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be noted that similar reference numerals and letters in the following drawings indicate similar items; therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings. It is also stated that the embodiments described below are for illustrative purposes only and are not intended to limit the invention.

[0022] It should be noted that the terms "installation," "setting," "connection," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly defined. Indications of orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are used only for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. The terms "first" and "second" are used only for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features.

[0023] Please see Figures 1 to 5 This embodiment provides a low-temperature transformer, including a frame 1, multiple sets of coils 2 wound on the frame 1, and a magnetic core 3 assembled with the frame 1. The frame 1, as the supporting structure of the entire transformer, provides a stable foundation for the winding of the coils 2. Its material and structural design have been carefully considered to ensure that it maintains good mechanical and electrical properties even in low-temperature environments. The magnetic core 3 works in conjunction with the frame 1, and through the coupling effect of the magnetic field, realizes the transformer's function of converting and transmitting electrical energy.

[0024] Each coil 2 has an infrared nano heat dissipation film 4 attached to its turns, layers, and surface. The infrared nano heat dissipation film 4 is an NIRC infrared nano heat dissipation film, consisting of a nano heat dissipation material layer, an aluminum foil layer, and an adhesive coating arranged sequentially from top to bottom. It has the following excellent properties: 1) Far-infrared emissivity up to 0.986, withstand voltage of 3000-6000V, and good thermal conductivity and insulation; 2) Easy to peel off, good adhesion, and convenient to use; 3) Compliant with RoHS / Reach standards, UL94 flame retardant rating V0, and meets EMC requirements for temperature resistance exceeding 150°C; 4) Customizable die-cutting, suitable for various shapes and applications; 5) Strong coating adhesion, good insulation performance, and no risk of short circuits in electronic components caused by graphene peeling.

[0025] By attaching infrared nano heat dissipation film 4 to the turns, layers, and surface (i.e., the core heat-generating area of ​​the transformer) of each coil 2, the Joule loss heat between turns and layers is quickly dissipated, blocking the accumulation of heat at its source, thus reducing the temperature of coil 2 and significantly reducing winding losses. Since the infrared nano heat dissipation film 4 has both high voltage resistance (3000-6000V) and high thermal conductivity, it replaces traditional insulating tape while achieving heat dissipation, avoiding heat retention caused by insulation layer obstruction and improving the overall working efficiency of the transformer. At the same time, the adhesive film adheres tightly, which can help fix coil 2, reduce the risk of loose winding, and eliminate the heat transfer gap between coil 2 and other components. Combined with the overall three-dimensional heat dissipation channel, it can further reduce the power supply volume or increase the power density. It should be noted that, depending on the actual application, the present invention may also apply infrared nano heat dissipation film 4 only between the turns of each coil 2, or only between the layers of each coil 2, or only on the surface of each coil 2, or only between the turns and layers of each coil 2, or only between the turns and surface of each coil 2, or only between the layers and surface of each coil 2.

[0026] In addition, infrared nano heat dissipation film 4 is also attached to the surface of the magnetic core 3 and between the magnetic core 3 and the frame 1. This film directly acts on the main areas where hysteresis loss and eddy current loss occur, quickly dissipating heat from the hot spots in the magnetic core 3, lowering its temperature, and preventing a decrease in permeability due to overheating, thus ensuring stable transformer conversion efficiency. The infrared nano heat dissipation film 4 fills the tiny gap between the magnetic core 3 and the frame 1, eliminating contact thermal resistance and improving the efficiency of heat transfer to the outside. Lowering the temperature of the magnetic core 3 reduces material aging and extends the transformer's service life. Simultaneously, the insulating properties of the infrared nano heat dissipation film 4 prevent electrical interference between the magnetic core 3 and the frame 1 and coil 2, further meeting safety certification requirements and adapting to more stringent application scenarios. It should be noted that, depending on the actual application, the present invention can also apply the infrared nano heat dissipation film 4 only to the surface of the transformer's magnetic core 3, or only between the transformer's magnetic core 3 and the frame 1.

[0027] In one embodiment, the width of the infrared nano heat dissipation film 4 attached between the turns of the coil 2 is the same as the turn spacing, the width of the infrared nano heat dissipation film 4 attached to the surface of the coil 2 is the same as the height of the winding cavity of the skeleton 1, and the width of the infrared nano heat dissipation film 4 attached to the transverse or longitudinal surface of the magnetic core 3 is the same as the width of the corresponding surface. This ensures that the heat dissipation contact area is maximized and avoids the film redundancy affecting the assembly.

[0028] In one embodiment, the present invention provides a method for manufacturing a low-temperature transformer, comprising the following steps: 1) The coil 2 is wound sequentially on the skeleton 1; wherein, when winding the coil 2 with a turn spacing, at least one turn of the first infrared nano heat dissipation film is attached between the turns of the coil 2, and the width of the first infrared nano heat dissipation film is adapted to the turn spacing of the coil 2. 2) After each set of coils 2 is wound, at least one ring of second infrared nano heat dissipation film is attached to the surface. The width of the second infrared nano heat dissipation film is the same as the height of the winding cavity of the skeleton 1. 3) After assembling the magnetic core 3 with the skeleton 1 after the coil 2 is wound, attach at least one (usually two) turn of the third infrared nano heat dissipation film to the transverse surface of the magnetic core 3. The width of the third infrared nano heat dissipation film is the same as the width of the transverse surface of the magnetic core 3. Attach at least one (usually two) turn of the fourth infrared nano heat dissipation film to the longitudinal surface of the magnetic core 3. The width of the fourth infrared nano heat dissipation film is the same as the width of the longitudinal surface of the magnetic core 3.

[0029] The above-described transformer manufacturing method utilizes a first infrared nano-heat dissipation film between the turns of coil 2 to remove Joule loss heat from the heat source. A second infrared nano-heat dissipation film on the surface of coil 2 collects the heat from the entire coil 2. The third and fourth films on the horizontal and vertical sides of the magnetic core 3 specifically dissipate hysteresis / eddy current loss heat, forming a fully enclosed heat dissipation network covering the interior of coil 2, the surface of coil 2, and the entire magnetic core 3. This significantly reduces the overall temperature of the transformer, relaxes the working magnetic flux density Bmax of the magnetic core 3, reduces the number of coils 2, saves copper wire, reduces material costs, reduces the space occupied by coil 2, and further improves power density. The width of the infrared nano-heat dissipation film 4 is adapted to the turn spacing, winding cavity height, and surface width of the magnetic core 3, ensuring maximum heat dissipation contact area while avoiding redundant film affecting assembly.

[0030] The present invention will be further described in detail below with reference to specific embodiments.

[0031] A method for manufacturing a transformer with 7 sets of coils 2 is as follows: 1) Pre-treatment of frame 1: Select PM-9823 model frame 1, check that the pins are not deformed and the slots are free of burrs, and ensure smooth wire entry and exit; 2) Coil 2 winding: Wind coil 2 in the order of N1-N7: N1 enters from PIN2-3 slot, is wound at X pin and hung on the top of PIN1 pin, leaving a buffer of 1.8mm; N2 and N3 enter from PIN1-2 slot, N2 exits from the small slot of PIN1, and the NC end is folded back into the coil; N6 enters from the top slot of PIN1 pin and exits from PIN3-4 slot, leaving a buffer of 1.8mm; During the winding of each group of coils 2, control the anti-tension within the set range to ensure that coil 2 is tight and not loose; 3) Film insulation and heat dissipation: When winding each set of coil 2, a first infrared nano heat dissipation film is applied between the turns of coil 2; after each set of coil 2 is wound, two second infrared nano heat dissipation films are immediately applied to the surface according to the specifications. 4) Assembly of magnetic core 3: Apply G657-3 adhesive evenly to the central column of magnetic core 3, ensuring a filling amount of ≥90%. Precisely assemble magnetic core 3 with frame 1, and press magnetic core 3 to ensure tight fit. Wrap 1.1 turns of 7mm self-adhesive copper foil along the wire wrapping direction at the connection of magnetic core 3, and solder the lead wire to PIN2 to ensure a firm solder joint without any cold solder joints. Apply two turns of the third infrared nano heat dissipation film to the transverse surface of magnetic core 3. Apply two turns of the fourth infrared nano heat dissipation film to the longitudinal surface of magnetic core 3.

[0032] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

[0033] The present invention has been described above with reference to the accompanying drawings. Obviously, the implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A low-temperature transformer, comprising a frame, a plurality of coils wound on the frame, and a magnetic core assembled with the frame, characterized in that, Each coil group has an infrared nano heat dissipation film attached between turns and / or between layers and / or on the surface, and the magnetic core has an infrared nano heat dissipation film attached to its surface.

2. The low-temperature transformer according to claim 1, characterized in that, An infrared nano heat dissipation film is attached between the magnetic core and the frame.

3. The low-temperature transformer according to claim 1, characterized in that, The infrared nano heat dissipation film is an NIRC infrared nano heat dissipation film, which includes a nano heat dissipation material layer, an aluminum foil layer and an adhesive coating arranged sequentially from top to bottom.

4. The low-temperature transformer according to claim 1, characterized in that, The width of the infrared nano heat dissipation film attached between the coil turns is the same as the turn spacing.

5. The low-temperature transformer according to claim 1, characterized in that, The width of the infrared nano heat dissipation film attached to the surface of the coil is the same as the height of the winding cavity of the skeleton.

6. The low-temperature transformer according to claim 1, characterized in that, The width of the infrared nano heat dissipation film attached to the transverse or longitudinal surface of the magnetic core is the same as the width of the corresponding surface.

7. A method for preparing a low-temperature transformer as described in any one of claims 1-6, characterized in that, Includes the following steps: The coils are wound sequentially on the frame; After each set of coils is wound, at least one second infrared nano heat dissipation film is attached to the surface. After assembling the magnetic core with the coil-wound frame, at least one ring of third infrared nano heat dissipation film is attached to the transverse surface of the magnetic core, and at least one ring of fourth infrared nano heat dissipation film is attached to the longitudinal surface of the magnetic core.

8. The method for preparing a low-temperature transformer according to claim 7, characterized in that, The width of the second infrared nano heat dissipation film is the same as the height of the winding cavity of the skeleton.

9. The method for preparing a low-temperature transformer according to claim 7, characterized in that, The width of the third infrared nano heat dissipation film is the same as the width of the transverse surface of the magnetic core, and the width of the fourth infrared nano heat dissipation film is the same as the width of the longitudinal surface of the magnetic core.

10. The method for preparing a low-temperature transformer according to claim 8, characterized in that, When winding a coil with a turn spacing, a first infrared nano heat dissipation film is attached between the coil turns.

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